Dodge - Grand Caravan Fwd - Workshop Manual - 1998 - 1998

Factory Workshop Manual Make Dodge Model Grand Caravan Fwd Engine and year V6-201 3.3L VIN R MFI (1998) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 9 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 14 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 15 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 16 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 27 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 28 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the junction block. On vehicles equipped with traction control, the fuse for the traction control switch is also located in the junction block. The junction block is located on the left hand front cowl panel on the vehicle. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 36 Controller Antilock Brakes Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 37 Controller Antilock Brakes Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 38 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch - Traction Control Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Ten Valves With Traction Control - Diagnostic Communication - Body Controller Communication - Traction Control Lamp Illumination Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control Unit (HCU). 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. CAB 25 Way Connector Unlocking CAB 25 Way Connector 4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of the HCU. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake tubes. 5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 41 Brake Tube Connections To HCU 6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. HCU To Suspension Cradle Mounting Bolts 7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember. 8. Remove HCU and the mounting bracket as a unit from the vehicle. HCU Mounting Bolts 9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 42 Pump Motor To CAB Wiring Harness 10. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 11. Remove the 4 bolts attaching the CAB to the valve block of the HCU. Remove/Install CAB 12. Remove the CAB from the valve block of the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 43 Electronic Brake Control Module: Service and Repair Installation Remove/Install CAB 1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit (HCU). CAB Attaching Bolts 2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). Pump Motor To CAB Wiring Harness 3. Plug the pump/motor wiring harness into the CAB. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 44 HCU Mounting Bolts 4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front suspension crossmember. HCU To Suspension Cradle Mounting Bolts 5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Brake Tube Connections To HCU Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 45 CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. 6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. Unlocking CAB 25 Way Connector 7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. Brake Tube Routing Clips 8. Install the routing clips on the brake tubes. 9. Lower vehicle. 10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 55 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 56 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 57 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 58 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM Improper Cooling Fan Relay Actuation > Page 64 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 70 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 71 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 72 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 73 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 78 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 84 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 90 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 91 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 92 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 93 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 94 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Relay Location Radiator Fan Relay Mounted On Left Front Frame Rail Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 95 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 96 Radiator Cooling Fan Motor Relay: Description and Operation Fig 41 Fan Control Module SOLID STATE FAN RELAY -- PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan motor will be 3.6 volts. when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101°C (214°F). When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. The SSFR is located on the left front inner frame -- just behind the radiator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 97 Radiator Cooling Fan Motor Relay: Testing and Inspection Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support. The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is properly attached to prevent the following: - Intermittent engine overheating. - Relay "thermal" shutdown, or relay damage. For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 103 Blower Motor Relay: Locations Rear Blower Relay Rear Blower Motor Relay This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 106 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 111 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Instrument Panel Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 120 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 123 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 124 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 125 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 126 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 127 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 128 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 129 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 130 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 131 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 132 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 133 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 134 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 135 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 136 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 137 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 138 Fog/Driving Lamp Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 140 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 141 Fog/Driving Lamp Relay: Electrical Diagrams Front Lighting (Part 2 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 142 Front Lighting (Part 3 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 143 Front Lighting (Part 6 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Description and Operation Headlamp Control Module: Description and Operation GENERAL INFORMATION Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to humid conditions. This is considered normal. The fogging will dissipate with increased ambient temperature or headlamp usage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Description and Operation > Page 147 Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure panel. Headlamp Module 4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from back of headlamp module. 6. Separate headlamp module from vehicle. INSTALLATION 1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel. 6. Verify headlamp operation and alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 154 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK. Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is OK, on one side of fuse, the fuse is blown, proceed to Step 3. 3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If amperage draw is greater than 20 amps without the horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded circuit exists between the horn relay and the horn. Proceed to step Step 5. 4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn switch or circuit is shorted. If the amperage draw does not drop to 0 amps, repair short at the Junction Block. 5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn sounds, replace the faulty horn. If amperage does not drop with both horns disconnected and the horn switch depressed, proceed to Step 6. 6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn relay to ground. If continuity is detected, the circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness. Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress horn switch and test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4. 3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay in the Junction Block. a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4. 4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors with horn switch depressed. a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO continuity, replace airbag cover. 6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 155 Horn And Connector 8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals of the wire harness. a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9. 9. With the horn switch depressed, test for voltage between the X2 circuit and ground. a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit between the relay and the horns. Horns Sound Continuously CAUTION: Continuous sounding of horns may cause relay to fail. The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1. Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay. 3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install horn relay into junction block. a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3 circuit from junction block to clockspring in steering in steering column. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 168 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 169 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 170 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 171 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 172 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 173 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 174 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 175 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 176 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 177 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM Auto Lamp DTC Diagnostics Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 186 Body Control Module Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 189 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 198 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 199 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 200 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 202 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 203 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 204 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 205 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 206 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Body Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Body Control Module: Electrical Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 210 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 211 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 212 Exterior Lighting (Park Lamps) Information Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 213 Instrument Cluster Interior Lighting Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 214 Power Door Locks W/Remote Keyless Entry (RKE) Power Door Locks W/O Remote Keyless Entry (RKE) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Radio (CCD) Without Infinity Sound Radio (CCD) With Infinity Sound Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Vehicle Communications Vehicle Theft Security System (VTSS) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 217 Windshield Wiper (Front) Windshield Wiper (Rear) Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 218 Body Control Module (Part 1 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 219 Body Control Module (Part 2 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 220 Body Control Module (Part 3 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 221 Body Control Module (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 222 Body Control Module (Part 5 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 223 Body Control Module (Part 6 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 224 Body Control Module (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following approved procedures is very important to the safety of individuals performing diagnostic tests. DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 227 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Servicing Sub-Assemblies Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced. DRBIII Safety Information WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: FUNCTION/INPUT LIMIT Volts 0 - 500 peak volts AC 0 - 500 volts DC Ohms (resistance)* 0-1.12 megohms Frequency Measured 0 - 10 kHz Frequency Generated 0 - 10 kHz Temperature -58 - 11000 F -50 - 600 C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ The circuit being tested must be protected by a 1OA fuse or circuit breaker. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code Body Control Module: Application and ID Body Code Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager Body Code = NS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code > Page 230 Body Control Module: Application and ID Glossary of Terms ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The following terms are used interchangeably: - Left Front (LF) Door & Driver (DR) Door - Right Front (RF) Door and Passenger (PASS) Door - "Gage" and "Gauge" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 233 Body Control Module: Description and Operation Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 234 Body Control Module: Description and Operation Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 235 Body Control Module: Description and Operation Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 236 Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 237 - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Compass Mini-Trip Computer (CMTC) The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Auto Headlamps On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless Entry (RKE) actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off the exterior lamps as described above. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Headlamp Time Delay The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body. Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. Identification of System Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 238 The vehicle systems that are part of the "body" system are: - airbag system - chimes - compass/mini-trip - courtesy lamps I panel dimming - headlamp time delay - illuminated entry - radio (CCD) - information center - mechanical instrument cluster (MIC) - power door locks - remote keyless entry (RKE) - vehicle communications - vehicle theft security system (VTSS) - wipers Vehicles equipped with the highline body control module can be identified by the presence of the vehicle theft security system (VTSS). Vehicles with the midline body control module may have a compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or illuminated entry. Vehicles with a base body control module will not have any of these features. Introduction Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover all the necessary requirements to begin a logical diagnostic path for each repair. If there is a trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are used to direct you alphabetically to the specific systems. NOTE: The following terms are used interchangeably: Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door Mechanical Instrument Cluster (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. Power Door Lock System When the body control module (BCM) receives an input for a lock request (door lock switch, RKE, or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power door lock features: Sliding Door Memory Lock When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay as described above, and will turn it on again when all sliding doors are closed. NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 239 RKE (Remote Keyless Entry) Interface The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Radio System There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 240 been activated. System Self-Test NOTE: System self-test can be entered only with the DRB. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Shipping Mode By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle. The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation System Coverage These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth Voyager vehicles equipped with either base, midline, or highline body control modules. Airbag Trouble Code Descriptions Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in the airbag section to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with "AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes An airbag trouble code becomes active and stored as soon as it is detected with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 241 malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire harness and connectors. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal Diagnostic 2 - AECM Internal Diagnostic 1 - AECM Output Driver - AECM Stored Energy - Internal Diagnostic 3 - Incorrect AECM For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - No CCD Communication - Driver Squib Circuit Shorted - Passenger Squib Circuit Open - Driver Squib Term Shorted to Battery - Passenger Squib Circuit Shorted - Driver Squib Term Shorted to Ground - Pass Squib Term Shorted to Battery - Loss of Ignition Run Only - Pass Squib Term Short to Ground - Loss of Ignition Run/Start - Warning Lamp Circuit Open - Output Driver Not Tested - Warning Lamp Circuit Shorted Driver Squib Circuit Open NAME OF CODE Driver Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring open or high resistance in clockspring - Driver side airbag module open - Driver airbag line 1 or line 2 open - Loose or poor connection at connector terminals Driver Squib Circuit Shorted NAME OF CODE Driver Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring short - Driver side airbag module short Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 242 - Driver airbag line 1 shorted to line 2 - Loose, or poor connector not completely connected Driver Squib Term Shorted to Battery NAME OF CODE Driver Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to voltage - Driver airbag line 2 short to voltage - Faulty clockspring - Faulty airbag control module Driver Squib Term Shorted to Ground NAME OF CODE Driver Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to ground potential - Driver airbag line 2 short to ground potential - Faulty clockspring - Faulty airbag control module Loss of Ignition Run Only NAME OF CODE Loss of Ignition Run Only NOTE: This code becomes active as soon as the condition is detected (this is not a stored code). WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Open ignition run circuit - Open fuse - Ignition run circuit short to ground - Loose or poor connection at connector terminals Loss of Ignition Run/Start NAME OF CODE Loss of Ignition Run/Start NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 243 - Open ignition run/start circuit - Open fuse - Ignition run/start circuit short to ground - Loose or poor connection at connector terminals Passenger Squib Circuit Open NAME OF CODE Passenger Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) open - Passenger airbag line 1 or line 2 open - Loose or poor connection at connector terminals Passenger Squib Circuit Shorted NAME OF CODE Passenger Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) short - Passenger airbag line 1 shorted to line 2 - Loose or poor connection at connector terminals Pass Squib Term Shorted to Battery NAME OF CODE Pass Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to voltage - Passenger airbag line 2 short to voltage - Faulty airbag control module Pass Squib Term Shorted to Ground NAME OF CODE Pass Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to ground potential Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 244 - Passenger airbag line 2 short to ground potential - Faulty airbag control module Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NAME OF CODE Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or during a lamp check. SET CONDITION With the voltage on, the airbag warning lamp driver circuit is other than expected. POSSIBLE CAUSES - Faulty warning lamp - Open fused ignition switch output circuit to Information Center - Airbag warning lamp driver circuit short to ground - Airbag warning lamp driver circuit short to voltage - Faulty information center printed circuit board - Loose or poor connection at connector terminal Output Driver Not Tested NAME OF CODE Output Driver Not Tested WHEN MONITORED At ignition on. SET CONDITION This code may set whenever another code is set due to any short to battery or short to ground failure of the squib circuits. If all other squib codes have been repaired and this code appears active by itself, the problem will be an internal failure of the airbag control module. POSSIBLE CAUSES - Short circuit to ground or to battery in either driver or passenger airbag lines - Defective airbag control module Trouble Code Testing Notes Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes. It is not necessary to perform all of the tests to diagnose an individual code. The body control module will set a diagnostic trouble code if a monitored input is determined to be malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the trouble code condition is removed, the body control module will back out the diagnostic trouble code if the trouble code condition remains cleared for twenty ignition cycles. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This will direct you to the specific test(s) that must be performed. ASB Message Not Received NAME OF CODE ASB Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from CAB every second. If this message is not received by the BCM for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from CAB to BCM Airbag Message Not Received Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 245 NAME OF CODE Airbag Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from ACM every second. It this message is not received by the BCM for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from ACM to BCM Battery Power to Module Disconnected NAME OF CODE Battery Power to Module Disconnected WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION Battery power to the BCM is disconnected while the ignition is on. THEORY OF OPERATION The body control module checks battery input and determines if the battery is connected. POSSIBLE CAUSES - In shipping mode - IOD fuse missing - Open wire - Blown IOD fuse EATX PRNDL Message Test Failed NAME OF CODE EATX PRNDL Message Test Failed WHEN MONITORED When engine is running. SET CONDITION The engine is running above 450 rpm and the body control module has not received a transmission PRNDL message. THEORY OF OPERATION The body control module will monitor the CCD bus and look for the transmission PRNDL message whenever the engine rpm is above 450. POSSIBLE CAUSES - Body Control module - Transmission control module - CCD bus failure - Loss of power to transmission control module EEPROM Checksum Failure NAME OF CODE EEPROM Checksum Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The sum of EEPROM constants does not equal the correct value. THEORY OF OPERATION By using a checksum, the BCM monitors the value of each programmable constant. The code is set if any value is incorrect. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 246 - Body Control module Front Wiper Park Switch CKT Open NAME OF CODE Front Wiper Park Switch Ckt Open WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Open wire - Wiper motor - Body Control module Front Wiper Park Switch CKT-Shorted NAME OF CODE Front Wiper Park Switch Ckt-Shorted WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Shorted wire - Wiper motor - Body Control module Fuel Level Sending Circuit Error NAME OF CODE Fuel Level Sending Circuit Error WHEN MONITORED With the ignition key on and battery voltage above 10 volts. SET CONDITION When the BCM senses an open or short on the fuel level sensor signal circuit. THEORY OF OPERATION The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be set. POSSIBLE CAUSES - Open wire - Shorted wire - Fuel level sending unit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 247 - Body control module Internal Module Test Failed NAME OF CODE Internal Module Test Failed WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The body control module performs an internal check and determines the body control module is not functioning properly. THEORY OF OPERATION The body control module performs internal diagnostics on demand and determines if the body control module microprocessor is functioning properly. POSSIBLE CAUSES - Body control module Left Door Key CYL Arm SW Failure NAME OF CODE Left Door key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Key CYL Disarm SW Failure NAME OF CODE Left Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Lock Switch Failure NAME OF CODE Left Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 248 SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Left Door Unlock Switch Failure NAME OF CODE Left Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Liftgate Key CYL Arm SW Failure NAME OF CODE Liftgate Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Key CYL Disarm SW Failure NAME OF CODE Liftgate Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 249 level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Door Mux CKT Short to GND NAME OF CODE Liftgate Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (Liftgate Switch MUX) - Body control module LT Front Door Mux Circuit Short to GND NAME OF CODE LT Front Door MUX Circuit Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (LF Door Switch MUX) - Body control module No CCD Message From PCM NAME OF CODE No CCD Message From PCM WHEN MONITORED When the ignition is in the run or start position and battery voltage is above 10 volts. SET CONDITION The BCM looks for engine messages over the CCD bus and does not receive a message within a 2-second period. THEORY OF OPERATION The body control module will monitor the engine messages after the ignition has been turned on. POSSIBLE CAUSES - Body control module - Powertrain control module - CCD Bus failure Rear Wiper Mux Circuit Error NAME OF CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 250 Rear Wiper MUX Circuit Error WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts. SET CONDITION When the rear wiper MUX circuit senses a voltage above 5.0 volts. THEORY OF OPERATION The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level. The voltage level will determine the wiper function to be performed. That level will be below 5.0 volts. POSSIBLE CAUSES - Circuit shorted to battery - Open CCM ground circuit Right Door Key CYL Arm SW Failure NAME OF CODE Right Door Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Key CYL Disarm SW Failure NAME OF CODE Right Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Lock Switch Failure NAME OF CODE Right Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 251 THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module Right Door Unlock Switch Failure NAME OF CODE Right Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module RT Front Door Mux CKT Short to GND NAME OF CODE RT Front Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below .4 volts on the RF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (RF Door Switch MUX) - Body control module Horn Switch Failure NAME OF CODE Horn Switch Failure WHEN MONITORED Continuously with battery connected and IOD fuse installed. SET CONDITION The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to cool down. POSSIBLE CAUSES - Shorted horn relay control circuit - Defective horn switch - Defective BCM Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 252 CCD Radio NAME OF CODE CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume Down Switch (Stuck) Preset Switch (Stuck) WHEN MONITORED Anytime ignition is on and voltage is above 10.0 volts. SET CONDITION When a switch is held active for longer than 20 seconds. THEORY OF OPERATION The BCM monitors the control switches for an active condition and performs the required radio function. When a switch is active for longer than 10 seconds, that switch function will be disabled until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be set. POSSIBLE CAUSES - Defective remote control switch - Shorted radio control MUX circuit Vehicle Communication The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 253 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Wiper System FRONT The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned off, the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. REAR The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics SELF DIAGNOSTIC TEST To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about five seconds) then release the buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarily appear. INSTRUMENT CLUSTER DTC CHART DTC ..................................................................................................................................................... .................................................... Description 110 ............................................................................... .......................................................................................................... Memory Fault in cluster 111 ..... .............................................................................................................................................................. ................... Calibration fault in cluster 905 ......................................................................................... ................................................................................ No CCD bus messages from TCM 921 .............. .............................................................................................................................................................. ......... Odometer fault from BCM 940 ................................................................................................... ...................................................................... No CCD bus messages from PCM 999 ........................ .............................................................................................................................................................. .................... End of Codes NOTE: For DTC testing see Condition Diagnostic Charts below. CONDITIONS Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis - Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis - Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis - Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis - Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis - Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis - Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21) CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). CLUSTER CALIBRATION TABLE Speedometer ....................................................................................................................................... ................................................. Calibration Point 1 ........................................................................................................................................................... ............................................... 0 mph (0 Km/h) 2 ................................................................................. ..................................................................................................................... 20 mph (40 Km/h) 3 ....... .............................................................................................................................................................. ................................. 55 mph (80 Km/h) 4 ........................................................................................... .......................................................................................................... 75 mph(120 Km/h) Tachometer ......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ............................................................... 0 rpm 2 ................................................................................ .................................................................................................................................... 1000 rpm 3 ..... .............................................................................................................................................................. ................................................. 3000 rpm 4 ........................................................................................ ............................................................................................................................ 6000 rpm Fuel Gauge .......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ......................................................... Empty(E) 2 ................................................................................. ................................................................................................................................... 1/8 Filled 3 ....... .............................................................................................................................................................. ............................................... 1/4 Filled 4 ........................................................................................... ............................................................................................................................ Full (F) Temperature Gauge ............................................................................................................................ ............................................... Calibration Point 1 ........................................................................................................................................................... .......................................................... Cold (C) 2 ................................................................................. .............................................................................................................................. Low Normal 3 ....... .............................................................................................................................................................. ......................................... High Normal 4 ............................................................................................ ........................................................................................................................... Hot (H) DIM TEST When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 256 no change, a problem exists in the cluster. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 257 Body Control Module: Scan Tool Testing and Procedures Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions. DRBIII Error Messages Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the scantool manufacturer for information and assistance. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 258 Body Control Module: Service and Repair Body Control Module Location REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4. Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION 1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5. Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker reinforcement. 8. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 259 Body Control Module: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge (0-300 psi) - Test Light - Voltmeter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Fig 1 Powertrain Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 265 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 268 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 270 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 272 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 273 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 274 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 275 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 276 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 277 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 278 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 279 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 280 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 281 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 282 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 283 Powertrain Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 284 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 285 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 286 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 287 Powertrain Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 288 Powertrain Control Module: Description and Operation Fig 1 Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Head Pressure - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Heated Oxygen Sensors (Upstream and Downstream) - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - SCI Receive - Speed Control System Controls - Throttle Position Sensor - Transaxle Park/Neutral Position Switch (automatic transaxle) - Transmission Control Module - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay - Automatic Shutdown (ASD) Relay - Data Link Connector - Electric EGR Transducer - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coil - Leak Detection Pump - Malfunction Indicator (Check Engine) Lamp - Proportional Purge Solenoid - Radiator Fan Control Module - Speed Control Solenoids - Tachometer Output - Torque Converter Clutch Solenoid (3 speed transmission) - Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 289 Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage - Engine coolant temperature - Exhaust gas content (oxygen sensors) - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs: Barometric pressure - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs: Air conditioning select switch head pressure - Brake switch - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) - Vehicle distance (speed) Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump. PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute pressure sensor, throttle position sensor and engine coolant temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 290 Powertrain Control Module: Service and Repair Fig 29 Power Distribution Center Retaining Screws REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29). Fig 30 Battery Heat Shield 3. Remove heat shield from battery (Fig 30). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 291 Fig 31 Battery Clamp 4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle. Fig 32 PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 292 Fig 33 PCM 40 Way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33). Remove both way connectors. Fig 34 PCM Removal/Installation 9. Remove 3 screws holding PCM to fender (Fig. 34). 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 293 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 299 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 302 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 304 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 306 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 307 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 308 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 310 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 311 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 312 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 313 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 315 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 316 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 318 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 321 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 326 Fuel Pump Relay: Diagrams Fuel Pump Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 327 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 328 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 334 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 335 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 337 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 338 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 339 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 341 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 342 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 345 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 347 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 348 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 351 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 353 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 356 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 361 Air Bag Control Module: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 362 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Airbag Module Locations Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag. The airbag cover/horn switch is serviced separately from the inflator and bag components. The Passenger Airbag Module is serviced as an assembly. WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY - LOWER STEERING COUPLER - STEERING WHEEL - STEERING COLUMN CLOCKSPRING - DRIVER AIRBAG COVER/HORN SWITCH - DRIVER AIRBAG MODULE - PASSENGER AIRBAG MODULE - UPPER INSTRUMENT PANEL WITH PAD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 363 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 364 Air Bag Control Module: Service and Repair WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module (ACM) to discharge. 2. Remove forward lower console from instrument panel. Heat Duct 3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from instrument panel. 5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 365 ACM Connectors 8. Disconnect two wire connectors from ACM. 9. Remove four bolts holding the ACM bracket assembly to floor. 10. Remove the ACM from vehicle. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 370 Engine Compartment Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 371 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 382 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 383 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 389 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 390 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 393 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 394 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 395 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 398 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 399 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 400 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 401 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 402 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 403 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 404 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 405 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 406 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 407 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 410 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 411 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 412 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 413 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 414 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 415 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 416 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 417 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 418 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 419 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 420 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 421 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 422 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 423 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 426 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 430 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 431 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL 1. Open the front door. Front Door Ajar Switch 2. Remove the screw holding the door ajar switch to the door B-pillar. 3 Remove the door ajar switch from the B-pillar. 4. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION - For installation, reverse the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 442 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL 1. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar switch. 4. Remove the sliding door ajar switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch REMOVAL 1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4. Remove the outer handle from the door. Door Lock Cylinder Switch 5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch from the door handle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch > Page 450 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 454 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches Remote Radio Switches Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right (Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 455 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. - Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL 1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 460 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection 1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror/Window Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test Power Mirror Switch: Testing and Inspection Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test > Page 474 Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck The mirror switches in the instrument panel have normally open contacts when in their inactive state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it then becomes connected to the P73/P70, circuits which are the mirror motor common connections. No faults will result from this action by itself. If one of the other switch contacts from the round portion of the switch becomes accidentally closed, It can cause problems such as both mirrors operating at the same time in the vertical or horizontal modes. Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the closed position, and the left/right portion is actuated to either side, a mirror motor will become actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this condition. - With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in the closed position, the mirror motor will not become actuated. During an ignition switch recall of a driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only if: - The closed switch contact was the same as the desired direction - Until the lack of a signal seen by the module shuts off the drive to the motor The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a single stuck contact could place an opposite mirror or direction into a series connection. This would run the connected motors at approximately half speed. Replace the mirror switch assembly to correct this condition. Mirror Mechanization Mirror Mechanization Table The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror mechanization show that both mirrors use the same functions. The rheostat for position sensing utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D and F. The ground return wire, E, stands alone. The mirror motors for each side use a common connection, B, which becomes automatically connected to the proper polarity power connection during either manual (through the mirror switch) or recall (through the Memory Seat/Mirror Module) modes of operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch Power Mirror Switch REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from headlamp switch bezel. 5. Remove power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 477 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp Power Mirror Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3. Pull bulb socket from back of power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward - Seat Front Down - Seat Rear Down - Recliner Rearward - Seat Track Forward - Seat Front Up - Seat Rear Up - Recliner Forward The inputs from these switches to the MSM Module is a current limited battery source fed by the MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All of these switch contact inputs to the module are normally closed to ground, except when actuated. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 481 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from seat. Power Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 485 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 486 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation Seat Memory Switch: Description and Operation SYSTEM OPERATION Memory Selector Switches The memory selector switches are mounted on the driver's door trim panel within easy reach of the driver. They provide a means to set or recall either of two positions of seat and recliner, and the side view mirrors as chosen by the driver. The inputs from these switches to the memory seat/mirror module is a ground level signal. 1. Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press any switches for 10 seconds. 4. To program the second driver's position, follow the above sequence. 5. To recall either of the programmed positions momentarily press and release either memory selector switch 1 or 2. Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Page 490 Seat Memory Switch: Testing and Inspection To test the memory selector switch: 1. Remove the memory selector switch. Refer to removal procedure. Memory Selector Switch Continuity 2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Page 491 Seat Memory Switch: Service and Repair REMOVAL 1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel. 2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 496 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level sensor. Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level sensor. Master Cylinder Brake Fluid Level Sensor 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid reservoir. 5. Connect the vehicle wiring harness connector to the brake fluid level sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 501 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 502 Traction Control Switch: Testing and Inspection REMOVAL AND INSTALLATION Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Refer to Switch Continuity Table. Switch Continuity Table Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 503 Traction Control Switch: Service and Repair Over Steering Column Bezel REMOVAL 1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control switch to the bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 900 - 1,300 ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 508 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Air Gap 0.014 - 0.059 in Rear Air Gap 0.020 - 0.054 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 511 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 514 Wheel Speed Sensor: Diagrams Rear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 515 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable. The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on the rear driveshaft. The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear driveshaft outboard constant velocity joint. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles to occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 516 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 519 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 520 Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 521 Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Rear Wheel Speed Sensor Attaching Bolt 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 522 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 523 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 524 Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or equivalent. Position Driver, Special Tool 6908-1 or equivalent with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 525 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 531 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 532 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 533 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 534 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 535 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Gauge Sending Unit ........................................................................................................................................................... 7 Nm (60 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 543 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5. See Stop lamp switch adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 544 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Speed Control Switches Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 548 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 552 Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for any of the following conditions: An indication of Park or Neutral - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction between the road surface and tires is extremely low) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached, then release the switch. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 553 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION - Reverse the preceding operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 562 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 568 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation SYSTEM OPERATION HVAC Mounted Switch HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 3. Remove sensor from vehicle. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION The rear blower speed switch controls the rear blower with the choice of low and high speeds. When the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. - Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one's digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cool-down test is exited. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 586 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION - For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions NUMBER: 26-03-98E GROUP: Miscellaneous DATE: March, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number 81-699-97028 DESCRIPTION OF CHANGES Revision to the Speed Control Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 591 76 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 592 78 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 593 80 Revision to the EGR System Failure Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 594 235 Revision to the A/C Pressure Sensor Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 595 292 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 596 296 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 597 A/C Pressure Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 598 A/C Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 603 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 607 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 612 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 613 Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 614 Brake Light Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 615 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 616 Brake Light Switch: Service and Repair REMOVAL Stop Lamp Switch 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALLATION NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 625 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 626 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 627 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 628 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 629 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 630 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 636 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 637 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 638 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 639 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 640 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 641 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation GENERAL INFORMATION The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 654 Headlamp Switch: Testing and Inspection Headlamp Switch Test Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch Headlamp Switch REMOVAL 1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 657 Headlamp Switch: Service and Repair Headlight Switch Lamp Headlamp Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5. Pull bulb socket from headlamp switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 664 Interior Light Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 665 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 669 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 670 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 680 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 681 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 684 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 685 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 686 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 687 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 688 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 689 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 690 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 691 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 692 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 694 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 695 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 697 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 698 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 699 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 700 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 701 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 704 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 705 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 706 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 707 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 708 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 712 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 713 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 714 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 715 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 716 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 720 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 723 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 726 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 728 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 729 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 731 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 732 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 733 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 734 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 735 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 736 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 737 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 740 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 742 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 743 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 744 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 745 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 746 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Tank Sending Unit Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 753 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 754 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 755 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 756 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor ........................................................................................................................................ .......................................................... 4 Nm (35 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 760 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 761 Map Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 762 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 763 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 92 Map Sensor Connector NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3 (Fig. 92). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (4.5 to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 764 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 9 MAP Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake manifold (Fig. 9). 3. Remove sensor from manifold. INSTALLATION - Reverse the above procedure for installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 769 Oxygen Sensor: Mechanical Specifications Upstream 02S ...................................................................................................................................... ......................................................... 27 Nm (20 ft lb) Downstream 02S ................................................................................................................................. ......................................................... 27 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 772 Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 773 Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector > Page 776 Downstream Heated Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 777 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 778 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 781 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 782 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground. - The white wires in the sensor connector are the power and ground circuits for the heater. - Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. 3. Resistance should be between 4 and 7 ohms. - If not replace the sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement Fig 122 Oxygen Sensor Grommet Cover WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122). Fig 123 Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123). Fig 124 Oxygen Sensor Removal & Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 785 - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 786 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Fig 121 Upstream Heated Oxygen Sensor The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121). CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 791 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 792 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 793 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 794 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 795 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 796 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 805 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 806 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 807 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 813 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 814 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 819 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 820 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 821 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 827 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 828 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 831 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 832 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 833 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 834 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 835 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 836 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 842 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM) transmits the vehicle speed signal to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 862 Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor. CIRCUIT OPERATION The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that information to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 863 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical OPERATION The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The speed and distance signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired MAP value. - Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine speed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 864 Vehicle Speed Sensor: Testing and Inspection For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 869 Fuel Low Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 873 Fuel Temperature Sensor Connector CNG Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 878 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 879 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 880 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 881 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 882 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 883 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 889 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 890 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 893 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 895 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 896 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 898 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 901 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 904 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 905 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 906 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 908 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 909 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 910 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 911 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 912 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 913 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 914 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 915 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 916 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 917 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 921 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 924 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 926 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 927 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 929 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 932 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 933 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 934 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 935 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 936 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 937 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 938 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 939 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 940 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 941 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 942 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 944 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 945 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 946 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 947 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 957 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 963 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 964 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 965 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 969 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 970 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 971 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 972 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 978 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 979 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 980 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 981 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 982 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 983 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 984 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 985 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 986 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 987 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 988 PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 989 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 990 POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 1007 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 1013 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1014 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1015 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1019 Connector Pin Identification Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1025 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1026 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1027 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1036 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1037 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1038 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1044 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 1045 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1050 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1051 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1052 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1058 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1059 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1062 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 1063 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1064 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1065 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1066 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1067 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1076 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1081 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1082 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1083 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb REMOVAL 1. Release hood latch and open hood. 2. From behind radiator closure panel, disengage wire connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring counter clockwise. 4. Disengage retaining ring from headlamp. 5. Pull headlamp bulb from back of headlamp. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. 1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Engage wire connector into headlamp bulb base. 5. Verify headlamp alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1095 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1100 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1101 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1102 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1110 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1115 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1116 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1117 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension Thumping Noise Suspension Travel Bumper: All Technical Service Bulletins Rear Suspension - Thumping Noise NO: 02-09-97 Rev. A GROUP: Suspension DATE: Oct. 24, 1997 SUBJECT: Thumping Noise At Rear Of Vehicle During Cold Operations THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB OR ALL WHEEL DRIVE (AWD).** SYMPTOM/CONDITION: Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has been in very cold temperatures (below 100 F.) for three hours or longer. DIAGNOSIS: After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over small bumps and listen for a thumping noise. The condition should improve if the temperature increases or the after the vehicle has been driven a few miles. If the thumping noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD) AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD) **NOTE: DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.** REPAIR PROCEDURE: This bulletin involves replacing the rear axle jounce bumpers. 1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise. 2. Separate the jounce bumper from the vehicle and discard. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension Thumping Noise > Page 1123 3. Install the appropriate revised jounce bumper specified in Parts Required. 4. Repeat steps 1 through 3 for the other side jounce bumper. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-04-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service Bulletins > Page 1124 Suspension Travel Bumper: Specifications To Frame Rail ...................................................................................................................................... ............................................... 33 Nm (290 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Service and Repair > Standard Suspension Travel Bumper: Service and Repair Standard NOTES: - There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with. - The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail. REMOVAL 1. Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. 2. Remove the jounce bumper from the frame rail. INSTALLATION 1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a torque of 33 Nm (290 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Service and Repair > Standard > Page 1127 Suspension Travel Bumper: Service and Repair Heavy Duty NOTES: - There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with. - The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail. REMOVAL 1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2. Remove the jounce bumper from the frame rail. INSTALLATION 1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm (290 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Locations > Compressed Natural Gas > Page 1131 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Page 1132 Suspension Travel Bumper: Specifications To Frame Rail ...................................................................................................................................... ............................................... 33 Nm (290 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information > Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. - Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one's digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cool-down test is exited. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information > Testing and Inspection > Page 1136 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION - For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information > Locations > Page 1139 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1145 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1146 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1147 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1148 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1149 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1150 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1151 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1152 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1153 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1154 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1155 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1156 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1157 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1158 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1159 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1160 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1161 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1162 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1166 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1167 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 1168 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 1169 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window and Vent Switch Test 1. Remove the driver or passenger door power window switch and bezel assembly from door trim panel. Power Window Master Switch Connector Driver Door Power Window Switch Test 2. Using an ohmmeter, Test driver door switch for continuity. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1174 4. If the results are not OK, replace the switch. The driver door power window switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1182 Windshield Washer Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Turn Signal Multi-Function Switch 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1186 Wiper Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Turn Signal Multi-Function Switch 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 783.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 802.5 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 1192 Alignment: Specifications With Tire Sizes P205/75/R14 or P215/65/R15 FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 747.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 766.0 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 1193 Alignment: Specifications With Tire Sizes P205/75/R15 or P215/65/R16 FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.05° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 753.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 772.0 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1194 Alignment: Service Precautions CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle alignment specifications, by heating and or bending. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Front-End Alignment Alignment: Description and Operation Front-End Alignment GENERAL INFORMATION Wheel alignment is the proper adjustment of all the interrelated suspension angles affecting the running and steering of the front and rear wheels of the vehicle. The method of checking front and rear wheel alignment will vary depending on the type of equipment being used. The instructions furnished by the manufacturer of the equipment should always be followed. With the exception that the wheel alignment specifications recommended by Chrysler Corporation should always be used. DESCRIPTION There are six basic factors which are the foundation to front wheel alignment. These are vehicle height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors only toe-in is normally mechanically adjustable on this vehicle. Camber Adjustment - is allowed in the event that a vehicle is involved in an accident and after repairs are made meeting manufacturers tolerance specifications, the camber setting will not meet manufacturers specifications. If camber adjustment is required, refer to the following Service Camber Adjustment Procedure for the required steps to be followed. CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle alignment specifications, by heating and or bending. CHECKS AND ADJUSTMENTS Alignment checks and adjustments should be made in the following sequence: 1. Camber 2. Toe Camber - is the number of degrees the top of the wheel and tire assembly is tilted inboard or outboard from a true vertical line. Inboard tilt is negative camber. Outboard tilt is positive camber. Excessive camber is a tire wear factor: negative camber causes wear on the inside of the tires tread surface, while positive camber causes wear to the outside of the tires tread surface. Toe - is measured in degrees or inches and is the distance the front edges of the tires are closer (or farther apart) than the rear edges. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Front-End Alignment > Page 1197 Alignment: Description and Operation Rear Alignment adjustment is not required. The rear axle alignment settings are preset at the factory and therefore no alignment is necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1198 Alignment: Testing and Inspection PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment factors. The following part inspection and the necessary corrections should be made to those parts which influence the steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be the same size and in good condition and have approximately the same wear. Note the type of tread wear which will aid in diagnosing, refer to Tires. 2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has the following areas inspected and or adjusted. Recommended tire pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated alignment rack. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and Camber Alignment: Service and Repair Checking Caster and Camber NOTE: All alignment specifications are to be checked and adjusted with the vehicle at its correct ride height. GENERAL INFORMATION Front suspension Caster and Camber settings on this vehicle are determined at the time the vehicle is designed. This is done by determining the precise mounting location of the vehicle's suspension components throughout the design and assembly processes of the vehicle. This is called a Net Build vehicle and results in no normal requirement to adjustment the Caster and Camber after a vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they should be checked during the alignment procedure to ensure they meet the manufacturers specifications. PROCEDURE If front camber does not meet the vehicle alignment specifications, it can be adjusted using a Mopar (R) Service Kit, or equivalent developed to allow for camber adjustment. If a vehicle's front camber does not meet required specifications, the vehicles suspension components should be inspected for any signs of damage or bending and the vehicle ride height should be checked to verify it is within required specification. This inspection must be done before using the Mopar (R) Service Kit for setting camber to the vehicle specification. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating bending or by performing any other modification to the vehicle's front suspension components. 1. Correctly position the vehicle on the alignment rack. Then install all required alignment equipment on the vehicle, per the alignment equipment manufacturers specifications. NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an equal number of times. Induce jounce (rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. 2. Correctly jounce vehicle and then read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and Toe-in. If front and rear camber readings are within required specifications proceed to Setting Front Toe for the Toe-in adjustment procedure if required. See: Front Alignment - If Camber readings are not within specifications refer to Setting Camber Adjustment and Cam Bolt Installation. See: Setting Camber Adjustment and Cam Bolt Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 1201 Alignment: Service and Repair Front Alignment 1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. 3. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front Toe to the preferred Toe specification. 4. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 5. Adjust steering gear to tie rod boots at tie rod. 6. Remove steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 1202 Alignment: Service and Repair Setting Camber Adjustment and Cam Bolt Installation 1. If the front camber readings obtained are not within the vehicle's specifications, use the following procedure and the Mopar (R) Clevis Bolt Service Kit, or equivalent to provide camber adjustment. The kit contains 2 flange bolts, 2 cam bolts, and 2 dog bone washers. These components of the service kit are necessary to assemble the strut to the steering knuckle, after modification of the strut clevis bracket. 2. Verify that the strut and steering knuckle are not bent or otherwise damaged. If either component is bent or show other signs of damage, replace required components and check the camber setting again. 3. If no component is bent or damaged, use the following procedure for modifying the strut clevis bracket and adjusting the camber setting. 4. Raise front of vehicle until tires are not supporting the weight of the vehicle. Then remove wheel and tire assembly from the location on the vehicle requiring the strut to be modified. CAUTIONS: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. - The steering knuckle strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 5. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard. Separate the steering knuckle from the Strut clevis bracket and position steering knuckle so it is out of the way of the strut. CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket. 6. Using an appropriate grinder and grinding wheel slot the bottom hole in both sides of the strut clevis bracket. When grinding slot do not go beyond the indentation area on the sides of the clevis bracket. CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the Mopar (R) Clevis Bolt Service Kit, or equivalent can be used to attach the steering knuckle to the strut after the mounting hole is slotted. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 1203 7. Install the flanged bolt from the Mopar (R) Clevis Bolt Service Kit, or equivalent into the top clevis bracket to steering knuckle mounting hole. Install the cam bolt into the bottom clevis bracket to steering knuckle mounting hole. 8. Install the dog bone washer on the steering knuckle to strut clevis bracket attaching bolts. Then install the nuts from the original attaching bolts onto the replacement bolts from the service kit. Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. 9. Lower vehicle until the full weight of the vehicle is supported by the vehicles' suspension. Then correctly jounce the front and rear of vehicle an equal amount of times. 10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket. When camber is correctly set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. 11. When vehicle is at correct camber setting torque both front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after required torque is met. 12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the preferred specification setting. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 1210 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1217 Idle Speed: Testing and Inspection THROTTLE BODY MINIMUM AIR FLOW CHECK Fig 97 Air Metering Fitting 6457 Fig 100 PCV Valve 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457 (0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link connector. 10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. 2.4L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 500-875 RPM Above 1000 Miles 550-875 RPM 3.0L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 560-910 RPM Above 1000 Miles 610-910 RPM 3.3L/3.8L Idle Specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1218 Odometer Reading Idle RPM Below 1000 Miles 525-875 RPM Above 1000 Miles 575-875 RPM 14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle purge line. 18. Remove DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig 125 Air Inlet Resonator REMOVAL 1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner housing halves together. Fig 126 Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing (Fig. 126). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1223 Fig 127 Air Cleaner Element 4. Remove element from air cleaner housing (Fig. 127). INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 1229 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1243 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". PURPOSE Transfer electrical current from the coil to the individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. CONSTRUCTION The spark plug cables and spark plug boots are made from high temperature silicone materials. Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. - The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. - They also identify proper heat shield installation on the boot for service. - All spark plug cable leads are properly identified with cylinder numbers. Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure. - Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. - Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. - The bottom of the spark plug heat shield must make contact with the spark plug hex. Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Service Life Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions. CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1246 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. - Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil pack and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. Secondary Ignition Cable Resistance Test Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables Ignition Cable: Service and Repair Replacing Cables Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. CAUTIONS: - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. - Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. - Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. SPARK PLUG CABLES #3 AND #5 Removal 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. - Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the retaining bracket. - Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. SPARK PLUG CABLE #1 Removal 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 5. Wipe spark plug insulator clean with a dry cloth before installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 1249 6. Remove the cable from the retaining bracket. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt, refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 1250 Ignition Cable: Service and Repair Cleaning Cables Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1254 Spark Plug: Service Precautions CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1255 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1256 Spark Plug: Description and Operation Fig 3 Platinum Plug Pads NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions. The recommended service life under severe conditions is 75,000 miles. - A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3). - Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's original spark plugs that have been determined good. - Do not apply anti-seize compound to new spark plugs. NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti-seize compound does not make contact with the spark plug electrodes or ceramic insulator. Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the procedures. Due to the engine packaging environment for this engine, extreme care should be used when installing the spark plugs to avoid cross threading problems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1259 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1260 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1261 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1262 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1263 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1264 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1265 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: - In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1266 Spark Plug: Adjustments Setting Spark Plug Gap - Typical Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1267 Spark Plug: Service and Repair Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. CAUTIONS: - Use extreme care when removing and installing the spark plug cables. - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. SPARK PLUG #3 AND #5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. SPARK PLUG #1 REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1268 insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt, refer to Cooling System. OTHER PLUGS REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Ratio .............................................................................................................................. ........................................................................... 8.9:1 Minimum Compression ................................... ........................................................................................................................................ 689.5 kPa (100 psi) Maximum Variation Between Cylinders ................................................................................ ......................................................................................... 25% Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1272 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters and are not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1284 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1289 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1290 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1291 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1297 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1302 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1303 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1304 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1305 Drive Belt: Specifications Belt Tension Chart Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1306 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1307 Accessory Drive Belt Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1308 Drive Belt: Adjustments Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts. Use belt tensioning Special Tool Kit C-4162 for: CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges are not interchangeable. - For conventional V-belts affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the belt tension for New or Used belt as prescribed in the Belt Tension Chart. - For a Poly-V belt affix the Poly-V Burroughs gauge to the belt and then apply specified tension to the belt as prescribed in the Belt Tension Chart. Belt Tension Chart Adjust belt tension for a New or Used belt as prescribed in the Belt Tension Chart. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation A/C Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Alternator Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1311 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Power Steering Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Water Pump Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1312 4. Reverse above procedure to install. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1313 Drive Belt: Service and Repair Cleaning and Inspection Serpentine Drive Belt Wear Patterns When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal these are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig 125 Air Inlet Resonator REMOVAL 1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner housing halves together. Fig 126 Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing (Fig. 126). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1319 Fig 127 Air Cleaner Element 4. Remove element from air cleaner housing (Fig. 127). INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation This engine uses filtered air to vent the crankcase. The filtered air is drawn through the resonator assembly located between the air cleaner and throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 1327 Fluid Filter - A/T: Service and Repair Fluid & Filter Change When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 1333 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Attaching Nipple .................................................................................................................... ................................................... 41 Nm (30 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1337 Oil Filter: Service and Repair Oil Filter CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications > Page 1341 Refrigerant Filter: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 1. Recover A/C system refrigerant. Filter Drier Assembly 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation, replace both refrigerant line O-rings. Then reverse the above procedure. Torque filter/drier mounting bolts to 45 in. lbs. +/- 10. 2. Evacuate and recharge system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations Heater Hose: Locations Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations > Page 1346 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 1349 Heater Hose: Service and Repair Underbody Plumbing Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 1350 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. For more information, refer to Heater core/ Service and Repair. See: Engine, Cooling and Exhaust/Cooling System/Heater Core/Service and Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Suction/Discharge Line - Service Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service NUMBER: 24-14-99 GROUP: Heating & A/C DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Suction And/Or Discharge Line Service MODELS: 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are torqued to 40 ft. lbs. (54 Nm). The root cause of A/C suction and/or discharge line cracking at or near the compressor may be related to the compressor being improperly secured to the engine. Excessive vibration may result if the compressor attaching bolts are not properly torqued. This vibration will eventually crack the aluminum tubing of the A/C lines and/or compressor mounting ears. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1355 Hose/Line HVAC: Locations Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1356 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1357 Hose/Line HVAC: Description and Operation SYSTEM OPERATION Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1358 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is dean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover A/C system refrigerant. Compressor Discharge Line 2. Remove discharge line mounting nut at compressor. Condenser Discharge Line 3. Remove discharge line at the top fitting on the condenser. INSTALLATION 1. For installation, reverse the above procedures. Replace all O-rings. Torque discharge line at condenser bolt to 180 in. lbs. +/- 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC Control Calibration Diagnostic and Cool-down test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1361 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9. Cover the openings to prevent contamination. 10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece assembly 13. Remove the old O-rings. INSTALLATION - For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1362 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve. Suction Line At Compressor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1363 9. Remove suction line mounting nut at compressor. 10. Remove suction line mounting bracket. 11. Remove suction line. INSTALLATION - For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1364 Hose/Line HVAC: Service and Repair Refrigerant Line Replacement Rear Air Conditioning Lines Rear Heater And A/C Lines Front Lines Connected To Rear Lines Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1365 Rear Heater Hose Connection Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. For more information, refer to Housing Assembly HVAC/ Service and Repair. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair Rear Heater A/C Air Outlets REMOVAL - Separate barrel from bezel by pulling outward. INSTALLATION - For installation, push the outlet firmly into the opening until it locks into place. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1374 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1375 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1376 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1377 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1378 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 1379 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed Technical Service Bulletin # 19-11-97 Date: 971205 Power Steering Line - Honk Noise At Low Speed NO: 19-11-97 GROUP: Steering EFFECTIVE DATE: Dec. 5, 1997 SUBJECT: "Honk" Noise During Parking Lot Maneuvers FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE BULLETIN 19-07-97. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. DIAGNOSIS: The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise can be reproduced during the diagnostic procedure. The noise may decrease in severity or disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings, replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic procedure is performed, will temporarily eliminate the noise for approximately 200 miles. Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering wheel back toward the right, repeat several times. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011 873AA Line, Power Steering Return AR 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-17-90 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing revised power steering pressure and return lines. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1384 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1. 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear, Figure 2. Discard the line and screw clamp. 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting, Figure 3. 9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2. Remove and discard the power steering pressure line. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1385 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line, Figure 4. 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line on to the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in. lbs.) Figure 2. 18. POWER STEERING FLUID LEVEL ADJUSTMENT NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1386 h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. 19. Verify correct steering operation and no fluid leaks. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1392 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1393 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1394 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1395 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1396 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1397 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed Technical Service Bulletin # 19-11-97 Date: 971205 Power Steering Line - Honk Noise At Low Speed NO: 19-11-97 GROUP: Steering EFFECTIVE DATE: Dec. 5, 1997 SUBJECT: "Honk" Noise During Parking Lot Maneuvers FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE BULLETIN 19-07-97. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. DIAGNOSIS: The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise can be reproduced during the diagnostic procedure. The noise may decrease in severity or disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings, replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic procedure is performed, will temporarily eliminate the noise for approximately 200 miles. Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering wheel back toward the right, repeat several times. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011 873AA Line, Power Steering Return AR 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-17-90 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing revised power steering pressure and return lines. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1402 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1. 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear, Figure 2. Discard the line and screw clamp. 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting, Figure 3. 9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2. Remove and discard the power steering pressure line. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1403 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line, Figure 4. 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line on to the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in. lbs.) Figure 2. 18. POWER STEERING FLUID LEVEL ADJUSTMENT NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 1404 h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. 19. Verify correct steering operation and no fluid leaks. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1405 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Routing Bracket To Suspension Cradle .................................................................................................................................................... 28 Nm (21 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE 1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. Power Steering Fluid Hose Routing Clip 3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle. Hose is removed from the top of the engine compartment. INSTALL CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This routing will prevent the power steering fluid supply hose from coming in contact with the accessory drive belt. 1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on fluid reservoir fitting. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on pump fitting. 5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is installed in a position to correctly align with stud in strut tower. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper let and let the fluid settle for at least two (2) minutes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1408 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1409 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if engine has been running. CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel tube connection. Remove the hose clamp from the power steering fluid return hose. Remove power steering fluid return hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid pressure line from the power steering pump pressure fitting. Drain excess power steering fluid from hose. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1410 6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle. 7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid pressure hose. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power steering pressure hose to the fittings on the power steering pump and steering gear. Route hose avoiding tight bends or kinking. Do not bend tube ends of the power steering hoses when installing. 4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. 5. Tighten all fasteners shown for specific applications to their correct torques listed below: - Pump End Tube Nut: 34 Nm (25 ft. lbs.) - Gear End Tube Nut: 34 Nm (25 ft. lbs.) - Pump Bracket Nut: 40 Nm (30 ft. lbs.) 6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1411 CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. 8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 9. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 1412 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if engine has been running. CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid return hose from the power steering pump return hose fitting. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route hose smoothly avoiding tight bends or kinking. Hose must remain away from the exhaust system and not come in contact with any unfriendly surfaces of the vehicle. 3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is to prevent overheating of the power steering fluid hoses. 5. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 6. After hoses are installed and power steering system is filled with fluid and caps installed on reservoir. Start the engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS AND STEAM TO ESCAPE THROUGH THE OVERFLOW TUBE. THIS WILL RELIEVE SYSTEM PRESSURE The hoses are removed by using constant tension clamp pliers to compress the hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar (R) equipment spring type clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1420 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1421 Brake Fluid: Service and Repair FLUID LEVEL CHECK Check master cylinder reservoir fluid level a minimum of twice annually. Master Cylinder Fluid Level Marks Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of the fluid reservoir with brake fluid. Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3, specifications. DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid ect. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY 2.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 10.6 L (11.23 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .................................................................. N/A Rear Heater ............................................................... ............................................................................................................................................. N/A 3.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ........................................................................................................................ 15.0 L (15.9 qts) 3.3/3.8L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) Trailer Tow Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) NOTE: Capacities include heater and coolant recovery tank filled to Max level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1426 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the radiator, where the tube/fin assemblies of these components can give it up to the air. The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar (R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion, when mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1429 Coolant: Description and Operation Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for each degree of temperature rise for each pound of water). This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F) - 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point to-22°C (-8°F). - 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed for 50/50 glycol. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -59°C (-50°F) CAUTION: Richer mixtures cannot be measured with field equipment. This can lead Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1430 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1435 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 1436 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 31TH .................................................................................................................................................... ............................................................. 8.0L (8.5 Qt) 41TE ................................................................. ................................................................................................................................................ 8.6L (9.1 Qt) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1439 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Transmission Fluid Type Type ......................................................................................................................................................... Mopar (R) ATF Plus 4 Type 9602, Or Equivalent Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1442 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 1443 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Capacity ............................................................................................................................................... ......................................................... 1.9L (4.0 Pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1448 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 85W-90 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1449 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit ............................................................................................................................. ........................................................ 1.2L (2.4 Pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1454 Fluid - Transfer Case: Fluid Type Specifications Power Transfer Unit Viscosity .............................................................................................................................................. .............................................................. SAE 85W-90 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1455 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.3L (4.5 Qt) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1460 Engine Oil: Fluid Type Specifications The content of this article reflects changes called for in TSB 26-11-97. Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C) ............................................. ....................................................................................................................................................... 10W-30 Below 32°F (0°C) ................................................................................................................... .................................................................................... 5W-30 If vehicle operates on E-85 fuel either full or part-time, use only Mopar Flexible Fuel 5w-30 engine oil or an equivalent that meets Chrysler standard MS-9214. SAE 5w-30 engine oil is preferred for use in Flexible Fuel engines. CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1461 Engine Oil: Description and Operation WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms to this service grade. SAE VISCOSITY Temperature/Engine Oil Viscosity An SAE viscosity grade is used to specify the viscosity of engine oil. Use only, engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Engine Oil Container Standard Notations Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1462 Engine Oil: Testing and Inspection To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has sat overnight. 3.0L Engine Dipstick Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1463 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1468 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1469 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 1470 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Capacity ............................................................................................................................................... ....................................................... 0.81 L (1.7 pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1473 Power Steering Fluid: Fluid Type Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page 1474 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. CAUTION: Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). In all pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.96 kg (34 oz. or 2.13 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 1.36 kg (48 oz. or 3.00 lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1479 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1480 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the liquid line near the strut tower. The low pressure service port is located on the suction line near the compressor manifold. Refrigerant Recovery/Recycling Station (Typical) When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label. Due to the different characteristics of R-134a it requires all new service procedures. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Compressor ......................................................................................................................... ............................................................ 150 ml 5.0 oz. Dual A/C Compressor .......................................................................................................................... ............................................................ 220 ml 7.4 oz. Dual A/C Evaporator ............................................................................................................................ .............................................................. 60 ml 2.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1485 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1486 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities Refrigerant Oil Level Check When all air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. 6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 1491 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 1492 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Bleeding Teves Mark 20 Hydraulic System The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 1498 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1504 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1505 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1506 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1507 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1508 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1509 Fuse: Locations Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1510 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1511 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1512 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Power Distribution Center > Page 1513 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block Fuse Block: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1518 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1519 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1520 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1521 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1522 Fuse Block: Diagrams Power Distribution Block Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1523 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1524 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1525 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1526 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Junction Block > Page 1527 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1533 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1534 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1535 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1536 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1537 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1538 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1539 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1540 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1541 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Junction Block > Page 1542 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation This vehicle does not have a Maintenance Reminder Light option. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1560 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1561 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1562 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1563 WHEEL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1564 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1565 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1566 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1567 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1573 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1574 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1575 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1576 WHEEL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1577 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1578 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1579 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 1580 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1581 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. Do not use replacement parts of lesser quality or of a substitute design from the original equipment part. All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety and handling of your vehicle. CAUTION: Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1584 Wheels: Testing and Inspection Tire and Wheel Runout NOTE: Runout should always be measured off the vehicle and on a suitable balance machine. GENERAL INFORMATION Radial run out is the difference between the high and low points on the outer edge of the tire or wheel. Lateral run out is the total side-to-side wobble of the tire or wheel. Radial run out of more than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral run out of more than 0.762 mm (0.030 inch) measured at the side of the tire as close to the tread as possible may cause the vehicle to shake. Sometimes radial run out can be reduced by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out to an acceptable level, the tire can be rotated on the wheel. (See Method 2). Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Fig. 2 Verify all wheel nuts are properly torqued. Fig. 3 Use run out gauge D-128-TR, or equivalent to determine run out. Relocate the wheel on the mounting studs, two studs over from the original position. Retighten wheel nuts until all are properly torqued. This will prevent brake distortion. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1585 Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run out and proceed to Method 2. Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run out in both tire and wheel. Remove tire from wheel and remount wheel on hub in former position. Fig. 5 Check wheel radial run out. It should be no more than 0.5 mm (0.020 inch) for steel wheels and 0.38 mm (0.015 inch) for cast aluminum wheels. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 1586 Fig. 6 Check wheel lateral run out. It should be no more than 0.8 mm (0.032 inch). If the point of greatest wheel radial run out is near the original chalk mark, remount the tire on the rim 180 degrees from its original position. Recheck the run out. If this does not reduce the run out to an acceptable level, replace the wheel and/or the tire. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance Wheels: Service and Repair Balance Balancing need is indicated by vibration of seats, floor pan, or steering wheel. The vibration will be noticed mostly when driving over 90 km/h (55 mph) on a smooth road. It is recommended that a two plane dynamic balancer be used when a wheel and tire assembly require balancing. Static balancing should be used only when a two plane balancer is not available. Off-vehicle tire and wheel balancing is recommended to be used on this vehicle. NOTE: If on vehicle equipment is being used to balance the tire/wheel assemblies, remove the opposite tire/wheel from the vehicle. Fig. 7 For static balancing, find the location of heavy spot on tire/wheel causing the imbalance. Counter balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer rim flange. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance > Page 1589 Fig. 8 For dynamic balancing, the balancing equipment is designed to indicate the location and amount of weight to be applied to both the inner and outer rim flanges. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance > Page 1590 Wheels: Service and Repair Installation Fig. 2 To install the wheel, first position it properly on the mounting surface of the hub using the hub pilot as a guide. All wheel nuts should be lightly tightened before progressively tightening them in the proper sequence. Then fully tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1594 Wheel Bearing: Description and Operation The rear hub and bearing assembly used on this vehicle is serviceable only as a complete assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort to repair it. The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are removable from the back of the rear hub/bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1595 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1596 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 5. Remove the 4 bolts attaching the hub/ bearing to the rear axle. CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1597 6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or equivalent and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or equivalent. Tighten bolt against Special Tool 8214-1 or equivalent. e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1 or equivalents. Removing Rear Hub/Bearing From Axle 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALL 1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1606 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ........................................................... ........................................................................................................................................................... 19 mm Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1607 Wheel Fastener: Specifications Wheel Stud Size Mounting Stud Size ............................................................................................................................. ........................................................... M12 x 1.5 mm Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1608 Wheel Fastener: Description and Operation The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and must be replaced with equivalent parts. If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Use the procedure and special tools shown in the service procedures section for the wheel mounting studs when replacing the wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. REMOVE The following procedure and special tools shown MUST BE used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove the front caliper assembly from the front steering knuckle assembly. Refer to Brakes and Traction Control for caliper removal procedure. 4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1611 5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are even with end of lug nut. Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel stud. 6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back over braking disc and align with caliper mounting holes on steering knuckle. Refer to Brakes and Traction Control for caliper installation procedure. Install the caliper adapter to steering knuckle attaching bolts and torque to 19 Nm (168 inch lbs.). 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Lower vehicle to the ground. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 1612 Wheel Fastener: Service and Repair Rear CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. REMOVE The following procedure and special tools shown MUST be used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the rear axle for replacement of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum. 4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the threads on stud are even with end of lug nut. Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel stud. 5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. Remove lug nut from stud and remove wheel stud from flange. INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 5. Lower vehicle to the ground. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Ratio .............................................................................................................................. ........................................................................... 8.9:1 Minimum Compression ................................... ........................................................................................................................................ 689.5 kPa (100 psi) Maximum Variation Between Cylinders ................................................................................ ......................................................................................... 25% Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1618 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service Camshaft Bearing: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service NUMBER: 09-007-02 GROUP: Engine DATE: Oct. 21, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Camshaft/Bearing Service MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG) Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES CODES EGA, EGB, EGH, EGM, EGP). DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings must be inspected for wear and/or damage. If wear or damage is present the short block must be replaced. Excessive camshaft bearing wear could result in damage to the new replacement camshaft. Camshaft bearings are only serviced with a short engine assembly. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1624 Camshaft Bearing: Specifications DIAMETER: No. 1 .............................................................................................................................................................. 50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2 .............................................................................................................................................................. 50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3 .............................................................................................................................................................. 50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4 .............................................................................................................................................................. 49.632 - 49.606 mm (1.9540 - 1.9529 inch) Oil Clearance ......................................................................................................................................................... 0.0254 - 0.0762 mm (0.001 - 0.003 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Technical Service Bulletins > Page 1625 Camshaft Bearing: Service and Repair REMOVAL 1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing core hole plug. Removed Installation Of Camshaft Bearings With Tool C-3132-A-Typical 2. Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each bearing shell to be removed and drive out bearing shells. INSTALLATION 1. Install new camshaft bearings with Tool C-3132-A by sliding the new camshaft bearing shell over proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing. Number two bearing must index with the oil passage to the left cylinder head and Number three bearing must index with the oil passage to the right cylinder head. If the camshaft bearing shell oil holes are not in exact alignment, remove End reinstall them correctly. Install a new core hole plug at the rear of camshaft. Be sure this plug does not leak. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Thrust Plate Bolt .................................................................................................................................. ............................................... 12 Nm (105 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service Camshaft: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service NUMBER: 09-007-02 GROUP: Engine DATE: Oct. 21, 2002 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Camshaft/Bearing Service MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG) Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES CODES EGA, EGB, EGH, EGM, EGP). DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings must be inspected for wear and/or damage. If wear or damage is present the short block must be replaced. Excessive camshaft bearing wear could result in damage to the new replacement camshaft. Camshaft bearings are only serviced with a short engine assembly. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 1636 Camshaft: Specifications Camshaft Drive .................................................................................................................................................... ..................................................................... Chain Bearings .............................................................. .............................................................................................................................. Steel Backed Babbitt Number .................................................................................................................................... ........................................................................................ 4 Diametrical Clearance ............................................................................................................................................... 0.025-0.101 mm (0.001-0.004 inch) Max Allowable ..................................................................................................................................... ................................... 0.127 mm (0.005 inch) Thrust Taken By .................................................................................................................................. ........................................................... Thrust Plate End Play .............................................................. ...................................................................................................... 0.127-0.304 mm (0.005-0.012 inch) Max. Allowable .................................................................................................................................... ................................... 0.304 mm (0.012 inch) Camshaft Journals Bearing Journal Diameter No. 1 ............................................................................................................................ 50.724-50.775 mm (1.997-1.999 inch) Bearing Journal Diameter No. 2 ........................................................................................................................ 50.317-50.368 mm (1.9809-1.9829 inch) Bearing Journal Diameter No. 3 ........................................................................................................................ 49.936-49.987 mm (1.9659-1.9679 inch) Bearing Journal Diameter No. 4 ........................................................................................................................ 49.530-49.581 mm (1.9499-1.9520 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Technical Service Bulletins > Page 1637 Camshaft: Service and Repair REMOVAL-ENGINE REMOVED FROM VEHICLE Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing chain. 1. Remove rocker arm and shaft assemblies. 2. Remove push rods and tappets; identify so each part will be replaced in its original location. Camshaft Thrust Plate 3. Remove camshaft thrust plate 4. Install a long bolt into front of camshaft to facilitate removal of the camshaft; remove camshaft, being careful not to damage cam bearings with the cam lobes. INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block. 2. Install camshaft thrust plate with two screws as shown in image. Tighten to 12 Nm (105 inch lbs.) torque. 3. Rotate crankshaft so the timing arrow is at the 12 o'clock position. 4. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 5. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. Alignment Of Timing Marks 6. Using straight edge to check alignment of timing marks. 7. Install the camshaft bolt. Tighten bolt to 54 Nm (40 ft. lbs.). 8. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up, remove cam sprocket and realign. 9. Measure camshaft end play. End Play should measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.) 0.310 mm (0.012 inch Max.). If not within limits install a new thrust plate. 10. Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications GENERAL SPECIFICATIONS Type ..................................................................................................................................................... .................................................... Roller Hydraulic Body Diameter ...................................................................................................................................................... 22.95-22.96 mm (0.9035-0.9040 inch) Clearance in Block .................................................................................................................................................... 0.02-0.06 mm (0.0007-0.0024 inch) Service Tappets Available ................................................................................ STD., 0.025 mm (0.001), 0.20 mm (0.008 inch), 0.762 mm (0.030 inch) TORQUE SPECIFICATIONS Tappet Retainer Yoke Bolt .............................................................................................................................................................. 12 Nm (105 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Diagnosis and Testing Lifter / Lash Adjuster: Testing and Inspection Diagnosis and Testing Roller Tappets Aligning Yoke And Retainer HYDRAULIC TAPPETS The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning yokes. The yokes are secured by an alignment yoke retainer. Preliminary Step To Checking The Hydraulic Tappets Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and check the oil level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 551.6 kPa) at 2000 rpm. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark. Either of these two conditions could be responsible for noisy tappets. Oil Level Check: stop engine after reaching normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. Oil Level Too High If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily. Oil Level Too Low Low oil level may allow pump to take in air which when fed to the tappets, causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out. Valve Train Noise Diagnosis To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet check valve not seating, or by foreign particles becoming wedged between the plunger and the tappet body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1643 Lifter / Lash Adjuster: Testing and Inspection Lash Adjuster Diagnosis A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour may be required. 3. During this time, turn engine off and let set for a few minutes before restarting. Repeat this several times after engine has reached normal operating temperature. 4. Low oil pressure. 5. The oil restrictor pressed into the vertical oil passage to the cylinder head is plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system. 10. Faulty lash adjuster. a. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. b. Remove suspected lash adjusters, and disassemble Do not reuse retainer caps. Do not interchange parts and make sure that care and cleanliness is exercised in the handling of parts. c. Clean out dirt and varnish with solvent. d. Reassemble with engine oil. e. Check for sponginess. f. If still spongy, replace with new adjuster. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation Lifter / Lash Adjuster: Service and Repair Removal and Installation 1. Refer to Cylinder Head Removal. Cylinder Head must be removed to gain access to tappets for service. 2. Remove yoke retainer and aligning yokes. 3. Use Tool C-4129 to remove tappets from their bores. If all tappets are to be removed, identify tappets to insure installation in original location. NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize and replace with oversize tappet. CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench. INSTALLATION 1. Lubricate tappets. 2. Install tappets in their original positions. Roller Tappets Aligning Yoke And Retainer 3. With roller tappets, install aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm (105 inch lbs.). 5. Install cylinder heads. Refer to cylinder head installation. 6. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1646 Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly Hydraulic Roller Tappet Assembly 1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check valve spring, check valve retainer and plunger spring. Check valve could be flat or ball. ASSEMBLY 1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear, valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve from seating, install a new tappet assembly. 4. Assemble tappets. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Shaft Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1650 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. Rocker Arm Location Left Bank 7. If rocker arm assemblies are disassembled for cleaning or replacement. Assemble rocker arms in their original position. Refer to image for rocker arm for positioning on the shaft. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 inch lbs.). CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts. Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine operation. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Bearing Clearance ........................................................................................................................................... 0.019 0.065 mm (0.00075 - 0.0026 inch) Wear Limit ........................................................................................................................................... ............................................ 0.76 mm (0.003 inch) Side Clearance ....................................................................................................................................................... 0.127 - 0.381 mm (0.005 - 0.015 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be marked at removal to insure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch) undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. Piston Ring Specification Chart 1. Follow procedure specified in the Standard Service Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance. Measure Crankshaft Journal O.D. NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts should be replaced. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced. 2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54 Nm + 1/4 turn (40 ft. lbs. + 1/4 turn). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1657 Checking Connecting Rod Side Clearance Check For Streched (Necked) Bolts CONNECTING ROD SPECIFICATION CHART 5. Using a feeler gauge, check connecting rod side clearance. Refer to Connecting Rod Specification Chart. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1658 Connecting Rod Bearing: Service and Repair Main Bearing and Connecting Rod Bearing Clearances PLASTIGAGE METHOD Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: NOTE: The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods: PREFERRED METHOD Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 inch) shim (e. g. cardboard, match-book cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14-20 Nm (10-15 ft. lbs.). The number of main bearing will vary from engine to engine. ENGINE WITH 5 MAIN BEARINGS - When checking #1 main bearing shim #2 main bearing. - When checking #2 main bearing shim #1 & 3 main bearing. - When checking #3 main bearing shim #2 & 4 main bearing. - When checking #4 main bearing shim #3 & 5 main bearing. - When checking #5 main bearing shim #4 main bearing. ENGINE WITH 4 MAIN BEARING - When checking #1 main bearing shim #2 main bearing. - When checking #2 main bearing shim #1 & #3 main bearing. - When checking #3 main bearing shim #2 & #4 main bearing. - When checking #4 main bearing shim #3 main bearing. NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE ALTERNATIVE METHOD The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked. PLASTIGAGE PROCEDURE 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. Plastigage Placed In Lower Shell 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1659 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch) off center and away from the oil hole. In addition, suspect areas can be checked by placing Plastigage in the suspect area. 4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. Clearance Measurement 5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 inch) replace bearing. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts TORQUE SPECIFICATIONS Rod Nut ............................................................................................................................................... ........................... 54 Nm (40 ft. lbs.) plus 1/4 turn Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1664 Connecting Rod: Specifications Connecting Rod Specifications Connecting Rod Bearing Type ....................................................................................................................................... ..................................... Aluminum Lead (Bimetal) Bearing Clearance ............................................................................................................................................... 0.019-0.065 mm (0.00075-0.0026 inch) Max. Allowable ..................................................................... ........................................................................................................ 0.076 mm (0.003 inch) Side Clearance ........................................................................................................................................................... 0.127-0.381 mm (0.005-0.015 inch) Connecting Rod Journals Diameter ............................................................................................................................................................ 58.005-57.979 mm (2.2837-2.2827 inch) Out-of-Round (Max.) .......................................................... ........................................................................................................... 0.025 mm (0.001 inch) Taper (Max.) .................................................................................................................................................. ................................ 0.025 mm (0.001 inch) TORQUE SPECIFICATIONS Rod Nut ............................................................................................................................................... ............................ 54 Nm (40 ft. lbs.) plus 1/4 turn Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1665 Connecting Rod: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. Identify Connecting Rod To Cylinder 4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. Connecting Rod Protectors 5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. INSTALLING PISTON AND CONNECTING ROD ASSEMBLY Piston Ring End Gap Position Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1666 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in image. 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. Piston-Installation 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. Piston I.D. Notches 7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9. Repeat procedure for each piston and rod installation. 10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level. 12. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Cast Nodular Iron Thrust Location No. 2 Bearing Connecting Rod Journal Diameter 2.124 - 2.125 in Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in Max. Allowable 0.004 in End Play 0.0036 - 0.0095 in Max. Allowable 0.015 in Main Bearing Journals Diameter 2.5202 - 2.5195 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Connecting Rod Journals Diameter 2.2837 - 2.2827 in Out-of-Round 0.001 in Taper (Max.) 0.001 in Main Bearing Cap Bolts 30 ft.lb plus 1/4 turn Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection Crankshaft Main Bearing: Service and Repair Inspection PLASTIGAGE METHOD Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: NOTE: The total clearance of the main bearings can only be determined by removing the weight of the crankshaft. This can be accomplished by either of two methods: PREFERRED METHOD Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum of 0.254 mm (0.010 inch) shim (e. g. cardboard, match-book cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14-20 Nm (10-15 ft. lbs.). The number of main bearing will vary from engine to engine. ENGINE WITH 5 MAIN BEARINGS - When checking #1 main bearing shim #2 main bearing. - When checking #2 main bearing shim #1 & 3 main bearing. - When checking #3 main bearing shim #2 & 4 main bearing. - When checking #4 main bearing shim #3 & 5 main bearing. - When checking #5 main bearing shim #4 main bearing. ENGINE WITH 4 MAIN BEARING - When checking #1 main bearing shim #2 main bearing. - When checking #2 main bearing shim #1 & #3 main bearing. - When checking #3 main bearing shim #2 & #4 main bearing. - When checking #4 main bearing shim #3 main bearing. NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE ALTERNATIVE METHOD The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the bearing being checked. PLASTIGAGE PROCEDURE 1. Remove oil film from surface to be checked. Plastigage is soluble in oil. Plastigage Placed In Lower Shell 2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 inch) off center and away from the oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. 3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths of a millimeter. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1672 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 inch) off center and away from the oil hole. In addition, suspect areas can be checked by placing Plastigage in the suspect area. 4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. Clearance Measurement 5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds 0.076 mm (0.003 inch) replace bearing. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1673 Crankshaft Main Bearing: Service and Repair Fitting Bearings CRANKSHAFT OIL CLEARANCE Crankshaft Specification Chart Measure Crankshaft Journal Measure the journal outside diameter as shown in image. Refer to Crankshaft Specification Chart. PLASTIGAGE (OIL CLEARANCE) MEASUREMENT 1. Remove oil from journal and bearing shell. 2. Install crankshaft. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Inspection > Page 1674 Measuring Bearing Clearance With Plastigage 3. Cut plastigage to same length as width of the bearing and place it in parallel with the journal axis. 4. Install the main bearing cap carefully and tighten the bolts to specified torque. CAUTION: Do not rotate crankshaft or the plastigage will be smeared. 5. Carefully remove the bearing cap and measure the width of the plastigage at the widest part using the scale on the plastigage package. Refer to Crankshaft Specification Chart for proper clearances. If the clearance exceeds the specified limits, replace the main bearing(s) and if necessary, have the crankshaft machined to next undersize. CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Type ..................................................................................................................................................... ...................................................... Cast Nodular Iron Bearing Type ................................................... ............................................................................................................................. Aluminum Lead (Bimetal) Thrust Location .................................................................................................................... ............................................................................ No. 2 Bearing Connecting Rod Journal Diameter ............................................................................................................................ 53.950-53,975 mm (2.124-2.125 inch) Main Bearing Diametrical Clearance No. 1-4 ............................................................................................................ 0.011-0.059mm (0.0043-0.0023 inch) Max. Allowable .................................................................................................. ............................................................................... 0.102 mm (0.004 inch) End Play ......................... ............................................................................................................................................... 0.09-0.24 mm (0.0036-0.0095 inch) Max. Allowable ........................................................................... ...................................................................................................... 0.381 mm (0.015 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1678 Crankshaft: Description and Operation An Access plug is located in the right inner fender shield. Remove the plug and insert the proper size socket, extension and ratchet, when crankshaft rotation is necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation Crankshaft: Service and Repair Removal and Installation MAIN BEARINGS Main Bearing Cap Identification Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable. CRANKSHAFT MAIN JOURNALS Measure Crankshaft Journal O.D. The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. Do NOT grind thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1681 Main Bearing Identification Upper and lower Number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersizes: 0.025 mm /0.001 inch) and 0.254 mm (0.010 inch). Never install an undersize bearing that will reduce clearance below specifications. REMOVAL 1. Remove oil pan and identify bearing caps before removal. Removing And Installing Upper Main Bearing With Special Tool C-3059 2. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059. into the oil hole of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. INSTALLATION NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1. Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4 main cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). 5. Rotate the crankshaft until number 6 piston is at TDC. 6. To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. then, move crankshaft all the way to the front of its travel. c. Wedge a appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in it's most forward position. d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs. + 1/4 Turn). Remove the holding tool. 7. Install oil pan. 8. Fill engine crankcase with proper oil to correct level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Removal and Installation > Page 1682 Crankshaft: Service and Repair Service Procedures DIAL INDICATOR METHOD Checking Crankshaft End Play 1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. Crankshaft Specification Chart 4. Move crankshaft all the way to the front and read the dial indicator. Refer to Crankshaft Specification Chart. FEELER GAUGE METHOD 1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface. Do not loosen main bearing cap. 2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to determine end play. Refer to Crankshaft Specification Chart. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1686 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3. Loosen screw in center of heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize system with Radiator Pressure Tool before looking for leaks. 5. Install power cord plug to heater. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Service and Repair Expansion/Freeze Plug: Service and Repair REMOVAL Core Hole Plug Removal Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems. INSTALLATION Thoroughly remove all rust and clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 inch.) inside the lead in chamfer. It is in not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley Chrankshaft Pulley Torque Specifications 54 Nm (40 ft.lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1694 Harmonic Balancer - Crankshaft Pulley: Specifications Harmonic Balancer/Vibration Damper Crankshaft Damper Pulley to Crankshaft Bolt .......................................................................................................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1695 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove right wheel and inner splash shield. 4. Remove drive belt. Crankshaft Damper-Removal 5. Remove crankshaft pulley. INSTALLATION Crankshaft Damper-Installation 1. Install crankshaft pulley. 2. Install drive belt. 3. Install inner splash shield and wheel. 4. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Type Material ....................................................................................................................................... .................................... Aluminum Alloy Tin Coated Clearance at Size Location .......................................................................................................................................... 0.025-0.057 mm (0.001-0.0022 inch) Weight (Standard Only)-3.3L ........................................................................................................................................ 381±5 grams (13.4394±0.1764 oz.) Weight (Standard Only)-3.8L ........................................................................................................................................ 438±5 grams (15.4501±0.1764 oz.) Pistons for Service ................................................................................ ........................................................................................................... Standard Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation Piston: Service and Repair Removal and Installation REMOVAL 1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. Identify Connecting Rod To Cylinder 4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if necessary. Connecting Rod Protectors 5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push each piston and rod assembly out of cylinder bore. NOTE: Be careful not to nick crankshaft journals. 6. After removal, install bearing cap on the mating rod. INSTALLING PISTON AND CONNECTING ROD ASSEMBLY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1701 Piston Ring End Gap Position 1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap. 2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located as shown in image. 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor. Be sure position of rings does not change during this operation. 4. Install connecting rod bolt protectors on rod bolts. Piston-Installation 5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. 6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. Piston I.D. Notches 7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps. Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9. Repeat procedure for each piston and rod installation. 10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1702 12. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1703 Piston: Service and Repair Fitting Pistons PISTONS Piston Measurements The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in image. Checking Cylinder Bore Size Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in image. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Removal and Installation > Page 1704 Refer to Cylinder Bore and Piston Specification Chart. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). RINGS Check Gap On Piston Rings 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. Refer to Piston Ring Specification Chart. 2. Check piston ring to groove clearance: Refer to Piston Ring Specification Chart. Piston Ring Specification Chart Piston Ring Specification Chart Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Type ..................................................................................................................................................... .............. Press Fit in Rod (Serviced as an Assembly) Diameter ......................................................... ..................................................................................................................... 22.88 mm (0.9009-0.9007 inch) Length ............................................................................................................... ............................................................ 67.25-67.57 mm (2.648-2.667 inch) Clearance in Piston @ 70° ........................................................................................................................................ 0.006-0.019 mm (0.0002-0.0007 inch) Clearance in Rod ................................................................... ........................................................................................................................... (Interference) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Number of Rings .................................................................................................................................. ............................................................................ 3 Compression ....................................................... .............................................................................................................................................................. 2 Oil Control ......................................................................................................................................... .............................................................................. 1 Oil Ring Type ..................................................... ........................................................................................................... 3-Piece, Steel Rail, Chrome Face Piston Ring Gap Top & 2nd Compressing Ring ................................................................................................................................... 0.30-0.55 mm (0.0118-0.0217 inch) Oil Control (Steel Rails) .......................................................................................................................................... 0.25-1.00 mm ((0.0098-0.0394 inch) Service Rings Ring Gap-Compression ......................................................................................................................................... 0.300-0.550 mm (0.0118-0.0217 inch) Ring Gap-Oil Control .............................................................................................................................................. 0.250-1.00 mm (0.0098-0.0394 inch) Piston Ring Side Clearance Top & 2nd Compression Rings ............................................................................................................................. 0.030-0.095 mm (0.0012-0.0037 inch) Oil Ring (Steel Rails ............................................................................................................................................. 0.014-0.226 mm (0.0005-0.0089 inch) Piston Ring Width Compression Rings ................................................................................................................................................... 1.46-1.50 mm (0.0575-0.0591 inch) Oil Ring (Steel Rails) .................................................................. ................................................................................................. 0.510 mm (0.0201 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1711 Piston Ring: Service and Repair PISTONS Piston Measurements The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in image. Checking Cylinder Bore Size Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in image. Refer to Cylinder Bore and Piston Specification Chart. Pistons and cylinder bores should be measured at normal room temperature, 70°F (21°C). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1712 RINGS Check Gap On Piston Rings 1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler gauge. Refer to Piston Ring Specification Chart. 2. Check piston ring to groove clearance: Refer to Piston Ring Specification Chart. Piston Ring Specification Chart Piston Ring Specification Chart Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters and are not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 1721 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Shaft Bracket Bolts .................................................................................................................. ............................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1725 Rocker Arm Assembly: Service and Repair REMOVAL 1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and shaft assembly. Rocker Arm Location Left Bank 7. If rocker arm assemblies are disassembled for cleaning or replacement. Assemble rocker arms in their original position. Refer to image for rocker arm for positioning on the shaft. INSTALLATION 1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions, tighten to 28 Nm (250 inch lbs.). CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts. Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine operation. 2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark plug wires. 6. Install upper intake manifold assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Bolts Non-isolated cylinder head cover .............................................................................................................................................. 12 Nm (105 inch lbs.) Isolated cylinder head cover ........................................................................................................................................................ 10 Nm (90 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications > Page 1729 Valve Cover: Service and Repair REMOVAL Cylinder Head Cover-Isolated Type NOTE: The cylinder head cover can be either an isolated type or a non-isolated type. Front Cylinder Head Cover 1. Disconnect ignition cables from spark plugs. 2. Disconnect crankcase vent hose from cylinder head cover. 3. Remove front cylinder head cover bolts. 4. Remove cylinder head cover and gasket. Rear Cylinder Head Cover 1. Disconnect negative cable from battery. 2. Remove Wiper Unit. Refer to Windshield Wipers and Washers for procedure. 3. Remove intake manifold upper plenum. 4. Disconnect PCV hose from cylinder head cover. 5. Remove rear cylinder head cover bolts 6. Remove cylinder head cover and gasket. INSTALLATION Front Cylinder Head Cover 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications: - Non-isolated cylinder head cover to 12 Nm (105 inch lbs.). - Isolated cylinder head cover to 10 Nm (90 inch lbs.). 4. Connect crankcase vent hose. 5. Connect ignition cables to spark plugs. Rear Cylinder Head Cover 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head cover bolts to the following specifications: - Non-isolated cylinder head cover to 12 Nm (105 inch lbs.). - Isolated cylinder head cover to 10 Nm (90 inch lbs.). 4. Connect PCV hose from cylinder head cover. 5. Install intake manifold upper plenum. 6. Install Wiper Unit. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Type ..................................................................................................................................................... ............................................. Powdered Metal Inserts Guide Bore Diameter ............................................................................................................................................... 7.975-8.00 mm (0.314 mm-0.315 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle-Intake and Exhaust ................................................................................................................... ..................................................................... 45-45.5° Runout (Max.) ...................................................................................................................................... ........................................... 0.0762 mm (0.003 inch) Width (Finish)-Intake ........................................................................................................................................................ 1.75-2.25 mm (0.069-0.088 inch) Width (Finish)-Exhaust ..................................................................................................................................................... 1.50-2.00 mm (0.057-0.078 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length (Approximately) .............................................................................................................................................................. 48.5 mm (1.909 inch) Wire Diameter ................................................................................................... .................................................................................. 4.75 mm (0.187 inch) Number of Calls ............. .............................................................................................................................................................. ..................................... 6.8 Spring Tension (Valve Closed) ........................................................................................................................................................ 95-100 lbs. @ 1.57 inch Spring Tension (Valve Open) ...................................................................................................................................................... 207-229 lbs. @ 1.169 inch Installed Height (Spring Seat to Bottom of Retainer) ....................................................................................................... 41.2-42.7 mm (1.622-1.681 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off Valve Spring: Service and Repair Cylinder Head Off REMOVAL Compress Valve Springs With Special Tool C-3422-B With Adapter 6412 1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412 as shown in image. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. Checking Valve Installed Height 2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to give 49.541 to 51.271 mm (1.950 to 2.018 inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip chamfer should be reground to prevent sea:. damage when the valve is installed. Valve Seal And Spring-Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1741 3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring Compressor Tool C-3422-B, with adapter 6412 install locks and release tool. If valves and/or seats are reground, measure the installed height of springs dimension B. make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Cylinder Head Off > Page 1742 Valve Spring: Service and Repair Cylinder Head On 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative cable from battery. 3. Remove air cleaner cover and hose assembly. 4. Remove upper intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke. 8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves in place while servicing components. 10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. 13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install Intake Manifold. 17. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications INTAKE VALVE Face Angle .......................................................................................................................................... ........................................................................... 44.5° Head Diameter .................................................................................................................................... ...................................................... 45.5 mm (1.79 in.) Length (Overall) ...................................................................................................................................................... 127.005-128.036 mm (5.000-5.041 in.) Minimum Valve Length After Tip Grinding ........................................................................................................................................... 124.892 (4.916 in.) Lift (Zero Lash) ................................................................................................................... ................................................................. 10.16 mm (0.400 in.) Stem Diameter (Standard) .............................................................................................................................................. 7.935-7.953 mm (0.312-0.313 mm) Valve Tip Height (From Cylinder Head Surface) ...................................................................................................... 49.541-512.271 mm (1.950-2.018 in.) Stem-to-Guide Clearance ................................................................................................................................................. 0.025-0.095 mm (0.001-0.003 in.) Max. Allowable (Rocking Method) ...................................................................................................................................................... 0.247 mm (0.010 in.) Valves for Service (Oversize Stem Diameters) - Standard - 0.015 mm (0.005 in.) - 0.040 mm (0.015 in.) - 0.080 mm (0.030 in.) EXHAUST VALVE Face Angle .......................................................................................................................................... .............................................................................. 45° Head Diameter .................................................................................................................................... .................................................... 37.5 mm (1.476 in.) Length Overall ......................................................................................................................................................... 127.825-128.465 mm (5.032-5.048 in.) Minimum Valve Length After Tip Grinding .................................................................................................................................... 125.512 mm (4.941 in.) Lift (Zero Lash) ................................................................................................................... ................................................................. 10.16 mm (0.040 in.) Valve Tip Height (From Cylinder Head Surface) ........................................................................................................ 49.541-51.271 mm (1.950-2.018 in.) Stem Diameter (Standard) ............................................................................................................................................ 7.906-7.924 mm (0.3112-0.3119 in.) Stem to Guide Clearance ................................................................................................................................................. 0.051-0.175 mm (0.002-0.006 in.) Max. Allowable (Rocking Method) ...................................................................................................................................................... 0.414 mm (0.016 in.) Valves for Service (Oversize Stem Diameters) - Standard - 0.015 mm (0.005 in.) - 0.040 mm (0.015 in.) - 0.080 mm (0.030 in.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL Compress Valve Springs With Special Tool C-3422-B With Adapter 6412 1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-B with adapter 6412 as shown in image. 2. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. Checking Valve Installed Height 2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve tip to give 49.541 to 51.271 mm (1.950 to 2.018 inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip chamfer should be reground to prevent sea:. damage when the valve is installed. Valve Seal And Spring-Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1748 3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring Compressor Tool C-3422-B, with adapter 6412 install locks and release tool. If valves and/or seats are reground, measure the installed height of springs dimension B. make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than 1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1749 Valve: Service and Repair Valve Service SERVICE RECONDITION Valve Inspection 1. Clean valves thoroughly and discard burned, warped and cracked valves. Valve Specification Chart 2. Measure valve stems for wear. Refer to Valve Dimension Chart. CAUTION: Valve stems are chrome plated and should not be polished. 3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4. Measure valve stem guide clearance as follows: a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of hose may be used to hold valve in place. Measuring Valve Guide Wear b. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1750 Valve Seats 5. Move valve to and from the indicator. Refer to Valve Guide Specification Chart. 6. Ream the guides for valves with oversized stems if dial indicator reading is excessive or if the stems are scuffed or scored. 7. Service valves with oversize stems and over size seals are available in 0.15 mm (0.006 inch), 0.40 mm, (0.015 inch) and 0.80 mm (0.030 inch) oversize. NOTE: Oversize seals must be used with oversize valves. 8. Refer to Valve Guide Specification Chart for reamer size to accommodate the oversize valve stems. 9. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do not attempt to rean1 the valve guides from standard directly to 0.80 mm (0.030 inch) Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015 inch) and 0.80 mm (0.030 inch) so the valve guides may be reamed true in relation to the valve seat. After reaming guides, the seat runout should be measured and resurfaced if necessary. See Refacing Valves and Valve Seats. Valve Guides NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize reamer, or if guide is loose in cylinder head. Refacing Valves And Valve Seats Valve Seats The intake and exhaust valves have a 44-1/2 to 45 degree face angle. The valve seats have a 45 to 45 1/2 degree face angle. The valve face and valve seat angles are shown in image. Valves Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1751 Valve Specification Chart 1. Inspect the remaining margin after the valves are refaced Refer to Valve Dimension Chart. Valve Seats Refacing Valve Seats CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head. 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1752 Valve Guide Specification Chart 4. When seat is properly positioned the width of intake seats should be 1.75 to 2.25 mm (0.059 to 0.088 inch) The width of the exhaust seats should be 1.50 to 2.00 mm (0.059 to 0.078 inch). Checking Valve Installed Height 5. Check the valve spring installed height after refacing the valve and seat. Testing Valve Springs Testing Valve Springs Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example; the compression length of the spring to be tested is 33.34 mm (1 5/16 inches). Turn table of Tool C-647 until surface is in line with the 33.34 mm (1 5/16 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1762 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1767 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1768 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1769 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage Number: 24-15-99 Group: Heating & A/C Date: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Compressor Lock-Up At Low Mileage OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. MODELS: 1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager (International Market) 1998 - **2000** (PL) Neon NOTE: THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR. SYMPTOM/CONDITION: The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN THE COMPRESSOR HAS FAILED. With the close internal clearances of a compressor operating in an R134A system, it is possible to experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system is inactive, the more likely the lock-up condition is to occur. This condition is the result of normal refrigerant movement within the A/C system caused by temperature differences between the various components (evaporator, condenser, compressor) that "washes" the oil out of the compressor. DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the A/C system is turned off perform the Repair Procedure. REPAIR PROCEDURE: This bulletin involves determining the extent of A/C compressor lock-up and either working the compressor loose or replacing it. Before assuming the A/C compressor has failed and must be replaced, the following steps should be taken. 1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate the compressor is internally damaged and must be replaced, skip to step 7. 2. Turn the hub clockwise five complete revolutions and remove the tool. 3. Start the vehicle, turn on the A/C system, and run at idle. 4. Observe the A/C compressor and system for normal operation for both cool-down and noise level standpoints. 5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system to operate at idle for 5 minutes. 6. If acceptable performance continues throughout the five minutes, the compressor does not need to be replaced, skip to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1775 7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the procedure outlined in the appropriate Service Manual to replace the A/C compressor. 8. Inspect the drive belt for damage, replace it if necessary. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs. 24-10-01-93 Replace Compressor 1.2 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1780 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1781 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1782 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1783 Drive Belt: Specifications Belt Tension Chart Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1784 Drive Belt: Description and Operation The accessory drive system utilizes two different style of drive belts. The conventional V-belt and the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump and water pump. Satisfactory performance of these belts depends on belt condition and proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the drive belts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1785 Accessory Drive Belt Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 1786 Drive Belt: Adjustments Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the vehicle on a hoist and the remove the splash shield to gain access to the drive belts. Use belt tensioning Special Tool Kit C-4162 for: CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges are not interchangeable. - For conventional V-belts affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the belt tension for New or Used belt as prescribed in the Belt Tension Chart. - For a Poly-V belt affix the Poly-V Burroughs gauge to the belt and then apply specified tension to the belt as prescribed in the Belt Tension Chart. Belt Tension Chart Adjust belt tension for a New or Used belt as prescribed in the Belt Tension Chart. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation Drive Belt: Service and Repair Removal and Installation A/C Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Alternator Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1789 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Power Steering Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install. Water Pump Belt REMOVE/INSTALL GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash shield. Accessory Drive Belt 3. Release tension by rotating the tensioner clockwise. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1790 4. Reverse above procedure to install. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1791 Drive Belt: Service and Repair Cleaning and Inspection Serpentine Drive Belt Wear Patterns When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal these are not reasons to replace the belt. However, cracks running along the rib (not across) are not normal. Any belt with cracks running along the rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Adjustments Engine Mount: Adjustments 1. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener and the fore and aft fasteners, and the front engine mount bracket to front crossmember screws. 3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. 4. Tighten engine mounts and fasteners in the following order: a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to 150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between the snubbers and the engine should be 2 mm (0.078 inch.) each side. c. Left engine mount through bolt to 75 Nm (55 ft. lbs.). 5. Recheck driveshaft length. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount REMOVAL 1. Support the engine and transmission assembly with a floor jack so it will not rotate. Engine Mounting-Front 2. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket. 3. Remove six screws from air dam to allow access to the front mount screws. 4. Remove the front engine mount screws and remove the insulator assembly. 5. Remove the front mounting bracket, if necessary. INSTALLATION 1. Reverse removal procedure for installation and tighten fasteners in this order: a. Tighten bolts 2,3, and 4 to 108 Nm (80 ft. lbs.). b. Tighten bolts 1 and 5 to 54 Nm (40 ft. lbs.). 2. Engine mount adjustment, Refer to Engine Mount Insulator Adjustment. 3. Install six screws to air dam and tighten to 12 Nm (105 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1797 Engine Mount: Service and Repair Left Mount REMOVAL 1. Raise vehicle on hoist and remove left front wheel. 2. Support the transmission with a transmission jack. 3. Remove the insulator through bolt from the mount. 4. Remove the transmission mount fasteners and remove mount. INSTALLATION 1. Reverse removal procedure for installation. 2. Tighten mount to transmission bolts to 55 Nm (40 ft. lbs.) Engine Mounting-Left 3. Tighten through bolt to 75 Nm (55 ft. lbs.). 4. Engine mount adjustment, Refer to Engine Mount Insulator Adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1798 Engine Mount: Service and Repair Rear Mount REMOVAL 1. Raise vehicle on hoist. 2. Support the transmission with a transmission jack so it will not rotate. 3. Remove the insulator through bolt from the mount and rear suspension crossmember. 4. Remove the four transmission mount fasteners and remove the mount. INSTALLATION Engine Mounting-Rear 1. Reverse the removal procedure for installation. Tighten through bolt to 75 Nm (55 ft. lbs.) Engine Mount Rubber Insulator Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right engine mount insulator. See Adjustments. Adjust drive train position, if required, for the following conditions: a. Drive shaft distress. See Suspension and Driveshafts. b. Any front end structural damage (after repair). c. Insulator replacement. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 1799 Engine Mount: Service and Repair Right Mount REMOVAL NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and harshness concerns. 1. Remove the purge duty solenoid and wiring harness from engine mount. Engine Mount-Right 2. Remove the two right engine mount insulator vertical fasteners and loosen the horizontal fastener, Do Not remove the large nut on the end of the core from frame rail. 3. Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. 4. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly INSTALLATION 1. Reverse removal procedure for installation. Tighten assembly in the following order: a. Engine mount to rail fasteners to 68 Nm (50 ft. lbs.). b. The vertical engine fastener to 102 Nm (75 ft. lbs.) c. The horizontal fastener to 150 Nm (111 ft. lbs.). 2. Install the purge duty solenoid and wiring harness to the engine mount. 3. Engine mount adjustment, Refer to Engine Mount Insulator Adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Idler Pulley: Customer Interest Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1808 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1809 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1810 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist Idler Pulley: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist Number: 07-02-99 Group: Cooling Date: June 4, 1999 SUBJECT: Serpentine Belt Slips Off Idler Pulley OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep snow or standing water. Snow or rain can enter the engine compartment from underneath the vehicle and force the serpentine belt oft of the idler pulley. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1816 DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.) from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure. PARTS REQUIRED: 1 04612412 Bracket, Engine Mount AR (1) 04861322 Belt, Serpentine REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1817 1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise (Figure 3). 2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount. 3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4), Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1818 4. Remove the load on the engine mount by carefully supporting the engine with a floor jack. 5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine mount assembly. 6. Remove the idler pulley from the engine mounting bracket. (Figure 3). 7. Remove the engine mounting bracket 8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.). 9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft lbs.) 10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new belt if there is any evidence of damage to the original one). 11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly release the belt tensioner. 12. Install the engine mount; torque the assembly in the following order, engine mount to rail fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm (111 ft. lbs.). 13. Install the purge duty cycle solenoid to the engine mount. 14. Start the vehicle and let it run for one minute then turn the engine off. 15. Verify the serpentine belt is properly aligned (Figure 1). 16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis will be required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 07-20-20-96 0.7 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Pressure at Idle (Engine Fully Warmed Up)* ............................................................................................................................. 34.47 kPa (5 psi) At 3000 rpm ............................................................................................................................................. ....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting ........................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Filter Type ................................................................................................... ..................................................................................................... Full Flow Oil Pressure Switch Actuating Pressure (Min) ........................................................................................................................................ 14-28 kPa (2-4 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1823 Engine Oil Pressure: Testing and Inspection Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM. Checking Oil Pump Pressure 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.3L (4.5 Qt) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1828 Engine Oil: Fluid Type Specifications The content of this article reflects changes called for in TSB 26-11-97. Engine Oil API Classification ................................................................................................................................. ........................................... SH or SH/CD or Above Above 0°F (-18°C) ............................................. ....................................................................................................................................................... 10W-30 Below 32°F (0°C) ................................................................................................................... .................................................................................... 5W-30 If vehicle operates on E-85 fuel either full or part-time, use only Mopar Flexible Fuel 5w-30 engine oil or an equivalent that meets Chrysler standard MS-9214. SAE 5w-30 engine oil is preferred for use in Flexible Fuel engines. CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage may result. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1829 Engine Oil: Description and Operation WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms to this service grade. SAE VISCOSITY Temperature/Engine Oil Viscosity An SAE viscosity grade is used to specify the viscosity of engine oil. Use only, engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. They are designated as either ENERGY CONSERVING or ENERGY CONSERVING II. CONTAINER IDENTIFICATION Engine Oil Container Standard Notations Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1830 Engine Oil: Testing and Inspection To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has sat overnight. 3.0L Engine Dipstick Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1831 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. TO CHANGE ENGINE OIL Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Attaching Nipple .................................................................................................................... ................................................... 41 Nm (30 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 1835 Oil Filter: Service and Repair Oil Filter CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. 1. Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. 2. Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 5. Start engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Bolts ..................................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Drain Plug ......................................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Level Sensor Plug ........................................................................................................................ .............................................................. 41 Nm (30 ft. lbs. Pressure Gauge Sending Unit ................. ................................................................................................................................................. 7 Nm (60 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation Oil Pan: Service and Repair Removal and Installation REMOVAL 1. Disconnect negative cable from battery and remove engine oil dipstick. 2. Raise vehicle on hoist and drain engine oil. 3. Remove bending brace to transaxle attaching bolt. 4. Remove bolts attaching dust cover to transaxle housing. Lower dust cover to gain access to oil pan bolts. 5. Remove oil pan screws and remove oil pan. INSTALLATION Oil Pan Sealing 1. Clean surfaces and apply a 1/8 inch bead of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, at the parting line of the chain case cover and the rear seal retainer. Oil Pan Gasket Installation 2. Use a new pan gasket. 3. Install pan and tighten screws to 12 Nm (105 inch lbs.). 4. Install dust shield and bending brace to transaxle housing. 5. Lower vehicle and install oil dipstick. 6. Connect negative cable to battery. 7. Fill crankcase with oil to proper level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Removal and Installation > Page 1841 Oil Pan: Service and Repair Cleaning and Inspection 1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.). 3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean oil screen and pipe in clean solvent. Inspect condition of screen. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Minimum Pressure at Idle (Engine Fully Warmed Up)* ............................................................................................................................. 34.47 kPa (5 psi) At 3000 rpm ............................................................................................................................................. ....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting ........................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Filter Type ................................................................................................... ..................................................................................................... Full Flow Oil Pressure Switch Actuating Pressure (Min) ........................................................................................................................................ 14-28 kPa (2-4 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1849 Engine Oil Pressure: Testing and Inspection Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5 psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM. Checking Oil Pump Pressure 1. Remove pressure sending unit and install oil pressure gauge. CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM. 2. Warm engine at high idle until thermostat opens. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation NO: 09-09-97 GROUP: Engine DATE: Dec. 19, 1997 SUBJECT: Gasket Surface Preparation On Aluminum Engine Components MODELS: 1995 (AA) Acclaim/Spirit 1995 (AJ) Lebaron Convertible 1995 (AS) Caravan/Voyager/Town & Country 1995 - 1998 (FJ) Avenger/Sebring/Talon 1995 - 1998 (JA) Breeze/Cirrus/Stratus 1996 - 1998 (JX) Sebring Convertible 1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1996 - 1998 (NS) Caravan/Voyager/Town & Country 1995 - 1998 (PL) Neon 1997 (PR) Prowler DISCUSSION: Many aluminum engine components are being received by the material return center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden scrapers are the only approved methods for removing gasket material. NOTE: DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR. Engine components received by the material return center will be evaluated for appropriate gasket removal procedures. Components returned with obvious damage caused by improper gasket removal procedures may be denied for warranty reimbursement. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Torque Sequence Intake Manifold Bolts Location And Tightening Sequence Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Torque Sequence > Page 1856 Intake Manifold: Specifications Torque Specifications DESCRIPTION .................................................................................................................................... ............................................................... TORQUE Throttle Body Mounting Bolts ............................................................................................................................................................ 23 Nm (200 inch lbs.) Lower Intake Mounting Bolts ............................................................................................................................................................. 23 Nm (200 inch lbs.) Upper Plenum Bolts ......................................................................................... ................................................................................... 28 Nm (250 inch lbs.) Plenum Support Bracket ................................................................................................................................................ ........................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1857 Intake Manifold: Description and Operation INTAKE/EXHAUST MANIFOLD The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for excellent engine tractability, response and usable power output. The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution. The exhaust manifolds are log type with a crossover and are attached directly to the cylinder heads. They are made from nodular cast iron. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1858 Intake Manifold: Testing and Inspection An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If a change in RPM'S, the area of the suspected leak has been found. 4. Repair as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection Intake Manifold: Service and Repair Cleaning and Inspection INSPECTION Check for: ^ Damage and cracks of each section. ^ Clogged water passages in end cross-overs (if equipped). ^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the sealing surface. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1861 Intake Manifold: Service and Repair Intake Manifold Replacement Removal 1. Remove windshield wiper module. 2. Perform fuel system pressure release procedure (before attempting any repairs). 3. Drain cooling system. 4. Remove air inlet resonator to throttle body hose assembly. 5. Remove throttle cable. Remove wiring harness from throttle cable bracket. 6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. 7. Remove EGR transducer connector. 8. Remove vacuum hose harness from throttle body. 9. Remove PCV and brake booster hoses from air intake plenum. 10. Disconnect MAP Sensor electrical connection. 11. Remove EGR tube flange from intake plenum. 12. Remove vacuum harness connectors from intake plenum. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1862 13. Remove cylinder head to intake plenum strut. 14. Remove the engine mounted ground strap. 15. Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel line. CAUTION: Wrap a shop towel around hoses to catch any gasoline spillage during removal. 16. Remove Direct Ignition System (DIS) coils and generator bracket to intake manifold bolt. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1863 17. Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt, and move bracket up so intake manifold can clear mounting studs. 18. Remove intake manifold bolts and remove the manifold. 19. Cover intake manifold with suitable cover when servicing. 20. Remove vacuum harness connector from Fuel Pressure Regulator. 21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance. 22. Disconnect cam sensor and coolant temperature sensor. 23. Remove fuel injector wiring clip from intake manifold water tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1864 24. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their ports. Intake Manifold Bolts Location And Tightening Sequence 25. Remove upper radiator hose, bypass hose and rear intake manifold hose. 26. Remove intake manifold bolts. Remove intake manifold. 27. Inspect and clean manifold. WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1865 28. Remove intake manifold seal retainers screws. Remove intake manifold gasket. Installation 1. Clean all surfaces of cylinder block and cylinder heads. 2. Place a drop (approximately 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant or equivalent, onto each of the four manifold to cylinder head gasket corners. 3. Carefully install the new intake manifold gasket. Torque end seal retainer screws to 12 Nm (105 inch lbs.). Intake Manifold Bolts Location And Tightening Sequence 4. Install intake manifold and bolts and torque to 1 Nm (10 inch lbs.). Then torque bolts to 22 Nm (200 inch lbs.) in sequence shown. Then torque again to 22 Nm (200 inch lbs.). After intake manifold is in place, inspect to make sure seals are in place. 5. Make sure the injector holes are clean and all plugs have been removed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1866 6. Lube injector O-ring with a drop of clean engine oil to ease installation. 7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. 8. Install the fuel rail attaching bolts and torque to 22 Nm (200 inch lbs.). 9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1867 10. Connect cam sensor and coolant temperature sensor. 11. Connect fuel pressure regulator vacuum line. 12. Remove covering on lower intake manifold and clean surface. 13. Place the new intake manifold gasket on lower manifold. Put upper manifold into place and install bolts and nuts finger tight. NOTE: At no time should the studs be replaced with a bolt and washer. 14. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not torque.) 15. Torque intake manifold bolts to 28 Nm (250 inch lbs.) following torque sequence. 16. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1868 17. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.). 18. Connect ground strap and MAP sensor electrical connectors. 19. Connect vacuum harness to intake plenum. 20. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm (200 inch lbs.). 21. Clip wiring harness into the hole in the throttle cable bracket. 22. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) motor. 23. Connect vacuum harness to throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Cleaning and Inspection > Page 1869 24. Install the Direct Ignition System (DIS) coils. Torque fasteners to 12 Nm (105 inch lbs.). 25. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion. 26. Install throttle cable. 27. Connect fuel injector wiring harness. 28. Install air cleaner and hose assembly. 29. Connect negative battery cable. 30. With the Diagnostic Readout Box (DRB) Scan Tool use Auto Shutdown (ASD) Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, The ASD Relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL Rear Crankshaft Oil Seal-Removal 1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the pry tool through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry tool INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. Rear Crankshaft Oil Seal-Installation 1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft. 2. Lightly coat seal O.D. with Mopar (R) Stud N' Bearing Mount Adhesive or equivalent. 3. Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing. Rear Crankshaft Seal Retainer When retainer removal is required, remove retainer and clean engine block and retainer of old gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. Remove right wheel and inner splash shield. 3. Remove accessory drive belt. Crankshaft Damper-Removal 4. Remove crankshaft damper. Front Crankshaft Oil Seal-Removal 5. Remove oil seal using Special Tool 6341. Be careful not to damage the crankshaft seal surface of cover. INSTALLATION Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1877 Crankshaft Oil Seal-installation 1. Install new seal using Special Tool C-4992. 2. Place seal into opening with seal spring towards the inside of engine. Install seal until flush with cover. Crankshaft Damper-Installation 3. Install crankshaft pulley using plate L-4524. Thrust Bearing/washer and C-4685-C1, 5.9 inch screw. 4. Install accessory drive belt. 5. Install inner splash shield and wheel. 6. Lower vehicle and connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Specifications Intake Manifold Gasket: Specifications Gasket Retaining Screws .................................................................................................................... ................................................. 12 Nm (105 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair 1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect negative cable from battery. 3. Remove air cleaner cover and hose assembly. 4. Remove upper intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw, turn engine so the number 1 piston is at Top Dead Center on the compression stroke. 8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1 spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to hold valves in place while servicing components. 10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. CAUTION: Do not pinch seal between retainer and top of valve guide. 12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. 13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14 Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install Intake Manifold. 17. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt ....................................................................................................................... .................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Number of Links .................................................................................................................................. .............................................................................. 64 Pitch ..................................................................................................................................................... ................................................................. 0.375 inch Width ................................................................................................................................................... .................................................................. 0.750 inch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch Timing Chain: Service and Repair Measuring Timing Chain Stretch 1. Place a scale next to timing chain so that any movement of chain may be measured. 2. Place a torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of crankshaft rotation to take up slack; 41 Nm (30 ft. lbs.) with cylinder head installed or 20 Nm (15 ft. lbs.) with cylinder heads removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block crankshaft to prevent rotation. Measuring Timing Chain Wear And Stretch 3. Holding a scale even, with dimension reading as shown, along edge of chain links. Apply torque in the reverse direction to 41 Nm (30 ft. lbs.) with cylinder heads installed, or 20 Nm (15 ft. lbs.) with cylinder heads removed. Check amount of chain movement. 4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not satisfactory, refer to Timing Chain Removal and Installation in this section. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Measuring Timing Chain Stretch > Page 1897 Timing Chain: Service and Repair Timing Chain Replacement REMOVAL 1. Disconnect negative cable from battery. 2. Remove timing chain cover. 3. Remove camshaft sprocket attaching bolt, and timing chain with camshaft sprocket. 4. Using a suitable puller remove the crankshaft sprocket. Be careful not to damage the crankshaft surface. INSTALLATION 1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain around crankshaft sprocket with the dark colored link lined up with the dot on the sprocket and install camshaft sprocket into position. Timing Marks Alignment 5. Use a straight edge to check alignment of timing marks. 6. Install camshaft bolt and washer. Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing marks do not line up remove cam sprocket and realign. 8. Check camshaft end play. With new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to 0.012 inch). Old thrust plate specification is 0.31 mm (0.012 inch) maximum. If not within these limits install new thrust plate. 9. Install timing chain cover and connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Bolt-M8 X 1.25 ..................................................................................................................................... ................................................... 27 Nm (20 ft. lbs.) Bolt-M10 X 1.5 ................................................... ..................................................................................................................................... 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1901 Timing Cover: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Support engine and remove right engine mount. 4. Raise vehicle on hoist. Drain engine oil. 5. Remove oil pan and oil pump pick-up. It may necessary to remove transaxle inspection cover. 6. Remove right wheel and inner splash shield. 7. Remove drive belt. 8. Remove A/C compressor and set aside. 9. Remove A/C compressor mounting bracket. Crankshaft Damper-Removal 10. Remove crankshaft damper. 11. Remove idler pulley from engine bracket. Engine Bracket 12. Remove engine bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1902 Timing Chain Case Cover 13. Remove cam sensor from chain case cover. 14. Remove chain case cover. INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement. NOTE: Do not use sealer on cover gasket. Timing Chain Case Cover Gaskets And O-Rings 2. Use a new cover gasket, and O-rings. Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is flush to 0.5 mm (0.020 inch) passed the lower edge of the cover. Refer to Oil Pan sealing. 3. Rotate crankshaft so that the oil pump drive flats are vertical. 4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats. 5. Install cover onto crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. 6. Install chain case cover screws and torque to 27 Nm (20 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1903 Crankshaft Oil Seal-Installation 7. Install crankshaft oil seal. Crankshaft Damper-Installation 8. Install crankshaft pulley. 9. Install engine bracket and torque fasteners to 54 Nm (40 ft. lbs.). 10. Install idler pulley on engine bracket. 11. Install cam sensor. Refer to Ignition System for installation procedure. 12. Install A/C compressor mounting bracket. 13. Install A/C compressor. 14. Install drive belt Refer to Cooling System for installation procedure. 15. Install inner splash shield and wheel. 16. Install oil pump pick-up and oil pan and transaxle inspection cover if removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling system. 20. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 1910 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1917 Idle Speed: Testing and Inspection THROTTLE BODY MINIMUM AIR FLOW CHECK Fig 97 Air Metering Fitting 6457 Fig 100 PCV Valve 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457 (0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link connector. 10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. 2.4L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 500-875 RPM Above 1000 Miles 550-875 RPM 3.0L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 560-910 RPM Above 1000 Miles 610-910 RPM 3.3L/3.8L Idle Specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1918 Odometer Reading Idle RPM Below 1000 Miles 525-875 RPM Above 1000 Miles 575-875 RPM 14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle purge line. 18. Remove DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig 125 Air Inlet Resonator REMOVAL 1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner housing halves together. Fig 126 Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing (Fig. 126). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1923 Fig 127 Air Cleaner Element 4. Remove element from air cleaner housing (Fig. 127). INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 1929 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1943 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". PURPOSE Transfer electrical current from the coil to the individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. CONSTRUCTION The spark plug cables and spark plug boots are made from high temperature silicone materials. Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. - The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. - They also identify proper heat shield installation on the boot for service. - All spark plug cable leads are properly identified with cylinder numbers. Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure. - Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. - Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. - The bottom of the spark plug heat shield must make contact with the spark plug hex. Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Service Life Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions. CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1946 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. - Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil pack and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. Secondary Ignition Cable Resistance Test Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables Ignition Cable: Service and Repair Replacing Cables Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. CAUTIONS: - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. - Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. - Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. SPARK PLUG CABLES #3 AND #5 Removal 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. - Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the retaining bracket. - Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. SPARK PLUG CABLE #1 Removal 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 5. Wipe spark plug insulator clean with a dry cloth before installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 1949 6. Remove the cable from the retaining bracket. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt, refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 1950 Ignition Cable: Service and Repair Cleaning Cables Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1954 Spark Plug: Service Precautions CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1955 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1956 Spark Plug: Description and Operation Fig 3 Platinum Plug Pads NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions. The recommended service life under severe conditions is 75,000 miles. - A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3). - Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's original spark plugs that have been determined good. - Do not apply anti-seize compound to new spark plugs. NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti-seize compound does not make contact with the spark plug electrodes or ceramic insulator. Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the procedures. Due to the engine packaging environment for this engine, extreme care should be used when installing the spark plugs to avoid cross threading problems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1959 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1960 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1961 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1962 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1963 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1964 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1965 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: - In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1966 Spark Plug: Adjustments Setting Spark Plug Gap - Typical Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1967 Spark Plug: Service and Repair Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. CAUTIONS: - Use extreme care when removing and installing the spark plug cables. - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. SPARK PLUG #3 AND #5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. SPARK PLUG #1 REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 1968 insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt, refer to Cooling System. OTHER PLUGS REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Ratio .............................................................................................................................. ........................................................................... 8.9:1 Minimum Compression ................................... ........................................................................................................................................ 689.5 kPa (100 psi) Maximum Variation Between Cylinders ................................................................................ ......................................................................................... 25% Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1972 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters and are not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Bolts Water Pump: Specifications Water Pump Pulley Bolts 250 in.lb Water Pump Mounting Bolts 105 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Water Pump Bolts > Page 1980 Water Pump: Specifications Water Pump Pulley Bolts Bolts ..................................................................................................................................................... .................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description and Operation Water Pump: Description and Operation The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain case cover, using an O-ring. for sealing. It is driven by the back surface of the Poly-V Drive Belt. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Description and Operation > Page 1983 Water Pump: Description and Operation General Information A quick test to tell whether the pump is working is to see if the heater warms properly. A defective pump can not circulate heated coolant through the long heater hose. The water pump on all models can be replaced without discharging the air conditioning system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 1984 Water Pump: Testing and Inspection Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of greenish-brown dried glycol running down the pump body and components below. A thin black stain below pump weep hole is considered normal operation. 3. Impeller rubs inside of chain case cover. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 1985 Water Pump: Service and Repair REMOVAL 1. Drain Cooling System. 2. Remove Poly-V Drive Belt. 3. Remove right front lower fender shield. 4. Remove pump pulley bolts and remove pulley. Water Pump 5. Remove pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSTALLATION Water Pump Body 1. Install new O-ring into groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105 inch lbs.) 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and torque to 30 Nm (250 inch lbs.). 5. Install drive belt. 6. Install right front lower fender shield. 7. Refill Cooling System. See Refilling Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM CAPACITY 2.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 10.6 L (11.23 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .................................................................. N/A Rear Heater ............................................................... ............................................................................................................................................. N/A 3.0L ENGINE Standard Duty Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ............................................................................................................................................. N/A Trailer Tow Front Heater ........................................................................................................................................ .............................................. 12.3 L (13.0 qts) Rear Heater ............................................................... ........................................................................................................................ 15.0 L (15.9 qts) 3.3/3.8L ENGINE Standard Duty Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) Trailer Tow Front Heater ........................................................................................................................................ ............................................ 12.5 L (13.23 qts) Rear Heater ............................................................... .................................................................................................................... 15.26 L (16.13 qts) NOTE: Capacities include heater and coolant recovery tank filled to Max level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1991 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the radiator, where the tube/fin assemblies of these components can give it up to the air. The use of aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection. Mopar (R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion, when mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed solution. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > General Information > Page 1994 Coolant: Description and Operation Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for each degree of temperature rise for each pound of water). This formula is altered when necessary additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F) - 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point to-22°C (-8°F). - 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of -37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat, temperature gauge, sending unit and heater are all designed for 50/50 glycol. CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene glycol and distilled water mix is recommended. Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of -59°C (-50°F) CAUTION: Richer mixtures cannot be measured with field equipment. This can lead Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 1995 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection Radiator Cooling Fan Motor: Testing and Inspection Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support. The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is properly attached to prevent the following: - Intermittent engine overheating. - Relay "thermal" shutdown, or relay damage. For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Testing and Inspection > Page 2000 Radiator Cooling Fan Motor: Service and Repair REMOVAL Fan Module There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as a assembly. 1. Raise the vehicle on hoist. 2. Remove the radiator outlet hose from hose retaining clip and remove clip from shroud. 3. Remove lower auxiliary transmission cooler lines from retaining clips on the fan module shroud, if equipped. 4. Lower the vehicle. Remove the air intake resonator from the throttle body and air cleaner assembly. 5. Disconnect the fans electrical connector located on the left side of the fan module. 6. Remove the Coolant Recovery System (CRS) attaching screw from the upper crossmember. 7. Remove upper grill to crossmember valence panel. 8. Disconnect the upper radiator mounts from the crossmember. Remove the upper crossmember. 9. Remove the air cleaner assembly. 10. Remove fan module retaining fasteners. 11. Remove upper auxiliary transmission cooler lines from retaining clips on the fan module shroud, if equipped. 12. Disconnect and plug the transmission line from the radiator fitting on the lower left side. 13. Raise vehicle on the hoist and remove the filter/drier, fan module and radiator mounting bolts located on the lower right of the module. 14. Lower the vehicle on hoist and remove the upper fan module to radiator retaining clips. 15. Remove the fan module from the vehicle. INSTALLATION 1. Install fan module assembly into attaching clips on the radiator. 2. Install the upper fan module to radiator retaining clips. 3. Raise vehicle on the hoist and install the filter/drier, fan module and radiator mounting fasteners located on the lower right of the module. 4. Lower the vehicle. Connect the transmission line to the radiator fitting on the lower left side. 5. Install the upper auxiliary transmission cooler lines to the retaining clips on the fan module shroud, if equipped. 6. Install fan module retaining fasteners. Tighten to 12 Nm (105 inch lbs.). 7. Install the air cleaner assembly. 8. Install the crossmember. Connect the upper radiator mounts to the crossmember. Tighten fasteners to 12 Nm (105 inch lbs.). 9. Install the Coolant Recovery System (CRS) attaching screw to the upper crossmember. Tighten to 2 Nm (18 inch lbs.). 10. Install upper grill to crossmember valence panel. 11. Connect the fans to the connector located on the left side of the fan module. 12. Install the air intake resonator to the throttle body and air cleaner assembly. 13. Raise the vehicle. Install the lower auxiliary transmission cooler lines to the retaining clips on the fan module shroud, if equipped. 14. Install outlet hose retainer clip to the shroud. Install the radiator outlet hose to the retaining clip. 15. Lower the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2009 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2010 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2011 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2012 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2018 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2024 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2025 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2026 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2027 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2032 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2038 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2044 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2045 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2046 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2047 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2048 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Relay Location Radiator Fan Relay Mounted On Left Front Frame Rail Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2049 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2050 Radiator Cooling Fan Motor Relay: Description and Operation Fig 41 Fan Control Module SOLID STATE FAN RELAY -- PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan motor will be 3.6 volts. when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101°C (214°F). When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. The SSFR is located on the left front inner frame -- just behind the radiator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2051 Radiator Cooling Fan Motor Relay: Testing and Inspection Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support. The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is properly attached to prevent the following: - Intermittent engine overheating. - Relay "thermal" shutdown, or relay damage. For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2056 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2057 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2058 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2059 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2060 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Gauge Sending Unit ........................................................................................................................................................... 7 Nm (60 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core REMOVAL 1. Drain coolant system. See: Service and Repair 2. Remove left side lower column cover. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Remove steering column assembly. See: Steering and Suspension/Steering/Steering Column/Service and Repair ABS Module 4. Remove ABS module, bracket and wiring. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair Interconnect And Bracket 5. Remove I/P to body harness interconnect and bracket. Lower Silencer Boot Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 2068 6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood. Heater Core Plate And Tubes 8. Remove heater core cover. Insert a small amount of towels under the heater core tubes. Remove heater core plate and tubes. Depress Clips 9. Depress heater core retaining clips. Accelerator Pedal 10. Pull up on accelerator pedal and slide heater core past. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 2069 Brake Pedal 11. Depress brake pedal and remove heater core from HVAC housing. INSTALLATION - For installation, reverse the above procedures. Install screws to retain heater core in housing. Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 N.m (27 ± 9 in. lbs.) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 2070 Heater Core: Service and Repair Rear Heater Core REMOVAL 1. Remove the lower right quarter trim panel. Heater Core Lines 2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4. Carefully pull the heater core and tubes up and straight out of the unit. INSTALLATION Filling Heater Core - For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor on HIGH - Discharge air temperature, measured at the dual register located on the C-pillar base, is between 57 degree Celsius to 62 degree Celsius (135 degree and 145 degree Fahrenheit). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Locations Heater Hose: Locations Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Locations > Page 2074 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 2077 Heater Hose: Service and Repair Underbody Plumbing Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 2078 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. For more information, refer to Heater core/ Service and Repair. See: Heater Core/Service and Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2085 Temperature Gauge: Component Tests and General Diagnostics Temperature Diagnosis (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2086 Temperature Diagnosis (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2087 Temperature Diagnosis (Part 3 Of 3) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock should not be removed unless leakage observed. Draincock Disassembled 1. Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to the end of the threads turn back 1/8 turn and, pull the stem from the radiator tank. INSTALLATION 1. Push the draincock assembly body into the tank opening until it snaps into place. 2. Tighten the draincock stem by turning clockwise until it stops. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation The radiator is equipped with a pressure cap that releases excessive cooling system pressure; maintaining a range of 97-124 kPa (14-18 psi). The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum through connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview Hold the cap in hand, right side up. The vent valve at the bottom of the cap should open. If the rubber gasket has swollen and prevents the valve from opening, replace the cap. Hold the cleaned cap in hand upside down. If any light shows between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold the vent shut. Replacement cap must be of the type designed for coolant reserve system with a completely sealed diaphragm spring, and rubber gasket to seal to filler neck top surface. This design assures coolant return to radiator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2097 Radiator Cap: Component Tests and General Diagnostics Radiator Cap - Pressure Testing Dip the pressure cap in water, clean any deposits off the vent valve or its seat and apply cap to end of Radiator Pressure Tool. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. See CAUTION below. If the pressure cap tests properly while positioned on Radiator Pressure Tool, but will not hold pressure or vacuum when positioned on the radiator. Inspect the radiator filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. CAUTION: Radiator Pressure Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. Radiator Cap to Filler Neck Seal - Pressure Relief Check The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at 55 kPa (8 psi) minimum. WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. There is no need to remove the radiator cap at any time except for the following purposes: 1. Check and adjust coolant freeze point. By adding or subtracting coolant through CRS bottle. 2. Refill system with new coolant. 3. Conducting service procedures. 4. Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS AND STEAM TO ESCAPE THROUGH THE OVERFLOW TUBE. THIS WILL RELIEVE SYSTEM PRESSURE The hoses are removed by using constant tension clamp pliers to compress the hose clamp. A hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all applications. If replacement is necessary replace with the original Mopar (R) equipment spring type clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2110 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2111 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2112 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2113 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2119 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2125 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2126 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2127 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2128 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2133 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2139 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2145 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2146 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2147 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2148 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2149 Radiator Cooling Fan Motor Relay: Locations Cooling Fan Relay Location Radiator Fan Relay Mounted On Left Front Frame Rail Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2150 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2151 Radiator Cooling Fan Motor Relay: Description and Operation Fig 41 Fan Control Module SOLID STATE FAN RELAY -- PCM OUTPUT The radiator fan runs at a variable speed depending on coolant temperature and A/C system pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR). A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR. Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan motor will be 3.6 volts. when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay and high speed ground relay when coolant temperature drops to approximately 101°C (214°F). When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F). Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan operates at low speed. The SSFR is located on the left front inner frame -- just behind the radiator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2152 Radiator Cooling Fan Motor Relay: Testing and Inspection Fan control is accomplished two ways. A pressure transducer on the compressor discharge line sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant temperature sensor which sends the message to the PCM. The fan will not run during cranking until the engine starts no matter what the coolant temperature is. CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support. The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is properly attached to prevent the following: - Intermittent engine overheating. - Relay "thermal" shutdown, or relay damage. For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2158 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2159 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2160 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2161 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2162 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Gauge Sending Unit ........................................................................................................................................................... 7 Nm (60 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2171 Temperature Gauge: Component Tests and General Diagnostics Temperature Diagnosis (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2172 Temperature Diagnosis (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2173 Temperature Diagnosis (Part 3 Of 3) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications TYPE The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. OPERATING RANGES Warm up They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 - 93°C (192 199°F). Fully Warm Engine They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2177 Thermostat: Description and Operation The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. They are designed to provide the fastest warm up possible by preventing leakage through them and to guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). They also automatically reach wide open so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2178 Thermostat: Service and Repair REMOVAL 1. Drain cooling system down below the thermostat level. Refer to Cooling System Draining. Thermostat, Housing, And Water Box 2. Remove thermostat housing bolts and housing. 3. Remove thermostat, discard gasket and clean both gasket sealing surfaces. INSTALLATION 1. Place a new gasket (dipped in water) on the thermostat housing surface, center thermostat into opening in the intake manifold water box. 2. Place housing and gasket over the thermostat, making sure thermostat is in the recess provided. 3. Bolt housing to intake manifold, tighten bolts to 28 Nm (250 inch lbs.). 4. Refill the cooling system to the proper level. Refer to Cooling System Refilling. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Bolts ..................................................................................................................................................... .................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Bolts Water Pump: Specifications Water Pump Pulley Bolts 250 in.lb Water Pump Mounting Bolts 105 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Water Pump Bolts > Page 2186 Water Pump: Specifications Water Pump Pulley Bolts Bolts ..................................................................................................................................................... .................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description and Operation Water Pump: Description and Operation The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain case cover, using an O-ring. for sealing. It is driven by the back surface of the Poly-V Drive Belt. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Description and Operation > Page 2189 Water Pump: Description and Operation General Information A quick test to tell whether the pump is working is to see if the heater warms properly. A defective pump can not circulate heated coolant through the long heater hose. The water pump on all models can be replaced without discharging the air conditioning system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 2190 Water Pump: Testing and Inspection Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump body. 2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of greenish-brown dried glycol running down the pump body and components below. A thin black stain below pump weep hole is considered normal operation. 3. Impeller rubs inside of chain case cover. 4. Excessively loose or rough turning bearing. NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole (black stain on water pump body). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis before replacing water pump. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 2191 Water Pump: Service and Repair REMOVAL 1. Drain Cooling System. 2. Remove Poly-V Drive Belt. 3. Remove right front lower fender shield. 4. Remove pump pulley bolts and remove pulley. Water Pump 5. Remove pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7. Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface. INSTALLATION Water Pump Body 1. Install new O-ring into groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105 inch lbs.) 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump. Install screws and torque to 30 Nm (250 inch lbs.). 5. Install drive belt. 6. Install right front lower fender shield. 7. Refill Cooling System. See Refilling Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter Technical Service Bulletin # J25 Date: 091030 Recall - Replace Mopar(R) Value Line Catalytic Converter October 2009 Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters Models 1997 - 1999 (AN) Dodge Dakota 1998 - 1999 (BE) Dodge Ram Truck 1995 - 1999 (BR) Dodge Ram Truck 1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon 1996 - 1997 (LH) Chrysler LHS and Concorde 1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country 1998 (PL) Plymouth Neon 2003 (PT) Chrysler PT Cruiser 1998 - 1999 (TJ) Jeep(R) Wrangler 2001 (WJ) Jeep(R) Grand Cherokee 1994 (XJ) Jeep(R) Cherokee 1994 - 1995 (YJ) Jeep(R) Wrangler 1993 - 1998 (ZJ) Jeep(R) Grand Cherokee NOTE: This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter installed. IMPORTANT: Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar Value Line catalytic converter was installed on about 47 of the above vehicles. These catalytic converters may fail an emissions inspection test. Repair The catalytic converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2201 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2202 Use the labor operation number and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE TORCH FLAME NEAR THE FUEL LINES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2203 1. Raise and support the vehicle on an appropriate hoist. 2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection. 4. Remove the exhaust clamp from the catalytic converter muffler connection. 5. Disconnect the oxygen sensor wiring. 6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal becomes cherry red. 7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from the exhaust pipe and the muffler. 8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter. 9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection. 10. Install the catalytic converter onto the exhaust pipe. 11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the alignment slot. 12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 45 ft. lbs. (61 N.m). 13. Connect the oxygen sensor wiring. 14. Lower the vehicle from the hoist. 15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. 16. Continue with Section B. Install the Authorized Modifications Label. B. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the Authorized Modifications Label. Then attach the label near the VECI label. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2204 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter Technical Service Bulletin # J25 Date: 091030 Recall - Replace Mopar(R) Value Line Catalytic Converter October 2009 Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters Models 1997 - 1999 (AN) Dodge Dakota 1998 - 1999 (BE) Dodge Ram Truck 1995 - 1999 (BR) Dodge Ram Truck 1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon 1996 - 1997 (LH) Chrysler LHS and Concorde 1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country 1998 (PL) Plymouth Neon 2003 (PT) Chrysler PT Cruiser 1998 - 1999 (TJ) Jeep(R) Wrangler 2001 (WJ) Jeep(R) Grand Cherokee 1994 (XJ) Jeep(R) Cherokee 1994 - 1995 (YJ) Jeep(R) Wrangler 1993 - 1998 (ZJ) Jeep(R) Grand Cherokee NOTE: This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter installed. IMPORTANT: Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar Value Line catalytic converter was installed on about 47 of the above vehicles. These catalytic converters may fail an emissions inspection test. Repair The catalytic converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2210 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2211 Use the labor operation number and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE TORCH FLAME NEAR THE FUEL LINES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2212 1. Raise and support the vehicle on an appropriate hoist. 2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection. 4. Remove the exhaust clamp from the catalytic converter muffler connection. 5. Disconnect the oxygen sensor wiring. 6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal becomes cherry red. 7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from the exhaust pipe and the muffler. 8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter. 9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection. 10. Install the catalytic converter onto the exhaust pipe. 11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the alignment slot. 12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 45 ft. lbs. (61 N.m). 13. Connect the oxygen sensor wiring. 14. Lower the vehicle from the hoist. 15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. 16. Continue with Section B. Install the Authorized Modifications Label. B. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the Authorized Modifications Label. Then attach the label near the VECI label. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 2213 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2214 Catalytic Converter: Service Precautions NOTE: There is no regularly scheduled maintenance on the catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country. REACTION The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. CATALYSTS The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2215 Catalytic Converter: Description and Operation Three Way Catalyst (TWC) PURPOSE Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and Oxides of Nitrogen (NOx)), by up to 90%. OPERATION Oxidation Reaction As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation (burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor (H2O) and Carbon Dioxide (CO2). This process no effect on NOx emissions. Reduction Reaction The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal of oxygen), reaction. OPERATING ENVIRONMENT A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only be achieved in a properly functioning feedback system with oxygen sensor. The ideal converter operating temperature, for maximum emission reduction and long service life is, 400°C - 800°C (750°F - 1500°F). Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede 1400°C (2500°F), which can melt substrate material. CONSTRUCTION Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately 2 grams of platinum and rhodium). CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material, reducing or eliminating catalyst activity. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Catalytic Converter: Initial Inspection and Diagnostic Overview VISUAL INSPECTION Inspect Catalytic converter for external cracks. Repair or replace as necessary. BACK PRESSURE CHECK If excessive exhaust back pressure is suspected, eliminate the exhaust system as a cause. If exhaust back pressure remains excessive with all mufflers disconnected, the catalytic converter may be plugged. LOOSE CORE CHECK If the exhaust system rattles during engine operation, check the catalytic converter for a loose core. With the vehicle raised (for access), tap the catalytic converter with a rubber mallet. If the converter rattles, the core is loose and the converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2218 Catalytic Converter: Component Tests and General Diagnostics Catalytic Converter Functional Test NOTE: If all other emission systems are functioning correctly, but vehicle still has excessive tailpipe emissions, the catalytic converter core may by contaminated. To check converter effectiveness, perform the following test: FUNCTIONAL CHECK 1. Warm the engine to normal operating temperature. 2. Run the engine at 2500 RPM for 30 seconds. 3. Using a pyrometer, measure the exhaust pipe temperature before and after the catalytic converter. 4. Exhaust pipe temperature should be at least 100° F hotter at the converter outlet than at the inlet. 5. If catalytic converter has little or no effect on exhaust temperature, the core may be contaminated. NOTE: If exhaust temperature exceeds 450° F, the engine may be running too lean. Repair the lean running condition and recheck exhaust temperature before condemning the catalytic converter. At Oxygen Sensor Opening Pressure Testing The Exhaust System at The Oxygen Sensor NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel system problems, then perform a visual inspection of the exhaust system. If the condition cannot be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT OXYGEN SENSOR OPENING 1. Carefully remove O2 sensor using proper tool. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust system backpressure reading on gauge. 4. If backpressure exceeds 1-1/4 psi (8.62 kPa), a restricted exhaust system is indicated. 5. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 6. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2219 NOTE: Prior to installing O2 sensor: - Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. - Coat sensor threads with a nickel based anti-seize compound (Loctite 771-64 or equivalent). Do not use graphite or other anti-seize compounds. Using Manifold Vacuum Port NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel system problems, then perform a visual inspection of the exhaust system. If the condition cannot be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT MANIFOLD VACUUM PORT 1. With engine at normal operating temperature, connect a vacuum gauge to any convenient manifold vacuum source. 2. Run engine at 1,000 rpm and record vacuum reading. 3. Increase rpm slowly to 2,500 rpm, and note vacuum reading at a steady 2.500 rpm. 4. If vacuum at 2,500 rpm decreases more than 3" Hg, from reading at 1000 rpm, the exhaust system should be inspected for restrictions. 5. Disconnect exhaust pipe from engine and repeat Step 3 & 4. If vacuum still drops more than 3" Hg, with exhaust disconnected, check for exhaust manifold restriction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 > Exhaust System - Droning Exhaust Crossover Pipe: Customer Interest Exhaust System - Droning NO: 11-03-98 GROUP: Exhaust DATE: Mar. 20, 1998 SUBJECT: Exhaust Drone MODELS: 1998 (NS) Town & Country/Caravan/Voyager 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Exhaust drone during: normal acceleration passing through 2100 RPM and 2800 RPM cruise at 65-70 MPH at 2100 RPM; light tip in at 70 MPH passing through 2,800 RPM; Wide Open Throttle (WOT) passing through 4100 RPM. DIAGNOSIS: Test drive the vehicle at per the conditions described above and listen for an exhaust drone. If an exhaust drone is heard, perform the Repair Procedure. PARTS REQUIRED: 2 04448149 Gasket, Crossover Flange 1 06504127 Nut 1 06100219 Nut 1 06504374 Bolt 2 06502058 Bolt REPAIR PROCEDURE: This bulletin involves modifying the exhaust crossover pipe support bracket. 1. Open the hood. 2. Remove the bolt attaching the crossover pipe support bracket to the engine. 3. Remove the four bolts attaching the crossover pipe to the exhaust manifold and separate the crossover pipe from the vehicle. 4. Mark the bolt slot in the support bracket of the crossover pipe as a guide to lengthen the slot 5 mm (3/16 in.) refer to Figure 1. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 > Exhaust System - Droning > Page 2228 5. Use a die grinder or file to enlarge the slot in the support bracket of the crossover pipe. 6. Discard the original crossover pipe flange gaskets. 7. Install the crossover pipe to exhaust manifolds using new flange gaskets, p/n 04448149. 8. Torque the crossover pipe to exhaust manifold attaching bolts to 54 Nm (40 ft. lbs.). 9. Torque the crossover pipe bracket to cylinder head attaching bolt to 54 Nm (40 ft. lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-10-01-90 0.7 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 > Exhaust System - Droning Exhaust Crossover Pipe: All Technical Service Bulletins Exhaust System - Droning NO: 11-03-98 GROUP: Exhaust DATE: Mar. 20, 1998 SUBJECT: Exhaust Drone MODELS: 1998 (NS) Town & Country/Caravan/Voyager 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Exhaust drone during: normal acceleration passing through 2100 RPM and 2800 RPM cruise at 65-70 MPH at 2100 RPM; light tip in at 70 MPH passing through 2,800 RPM; Wide Open Throttle (WOT) passing through 4100 RPM. DIAGNOSIS: Test drive the vehicle at per the conditions described above and listen for an exhaust drone. If an exhaust drone is heard, perform the Repair Procedure. PARTS REQUIRED: 2 04448149 Gasket, Crossover Flange 1 06504127 Nut 1 06100219 Nut 1 06504374 Bolt 2 06502058 Bolt REPAIR PROCEDURE: This bulletin involves modifying the exhaust crossover pipe support bracket. 1. Open the hood. 2. Remove the bolt attaching the crossover pipe support bracket to the engine. 3. Remove the four bolts attaching the crossover pipe to the exhaust manifold and separate the crossover pipe from the vehicle. 4. Mark the bolt slot in the support bracket of the crossover pipe as a guide to lengthen the slot 5 mm (3/16 in.) refer to Figure 1. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 > Exhaust System - Droning > Page 2234 5. Use a die grinder or file to enlarge the slot in the support bracket of the crossover pipe. 6. Discard the original crossover pipe flange gaskets. 7. Install the crossover pipe to exhaust manifolds using new flange gaskets, p/n 04448149. 8. Torque the crossover pipe to exhaust manifold attaching bolts to 54 Nm (40 ft. lbs.). 9. Torque the crossover pipe bracket to cylinder head attaching bolt to 54 Nm (40 ft. lbs.). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-10-01-90 0.7 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Technical Service Bulletins > Page 2235 Exhaust Crossover Pipe: Specifications Fasteners ............................................................................................................................................. ...................................................... 54 Nm (40 ft. lbs.) Flange Fastener .............................................. ..................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 200 in.lb Exhaust Manifold Flange (All) Fastener 250 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2239 Exhaust Manifold: Description and Operation INTAKE/EXHAUST MANIFOLD The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for excellent engine tractability, response and usable power output. The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution. The exhaust manifolds are log type with a crossover and are attached directly to the cylinder heads. They are made from nodular cast iron. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation Exhaust Manifold: Service and Repair Removal and Installation REMOVAL 1. Disconnect battery negative cable. 2. Remove accessory drive belt. Refer to Accessory Drive section located in Engine for procedure. 3. Remove generator. 4. Raise vehicle and disconnect exhaust pipe from rear (cowl side) exhaust manifold at flex-joint. 5. Disconnect down stream oxygen sensor connector. 6. Lower exhaust system to gain access to rear manifold. 7. Separate EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire. 8. Remove heat shield from rear engine mount. EGR Tube, Heated Oxygen Sensor And Generator/power Steering Strut 9. Remove Generator/Power Steering Support Strut. 10. Remove bolts attaching crossover pipe to manifold. 11. Disconnect up stream oxygen sensor connector. 12. Remove bolts attaching rear manifold to cylinder head and remove manifold. Heat Shield-Front 13. Lower vehicle and remove screws attaching front heat shield to front manifold. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 2242 Crossover Pipe 14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head. Remove assemblies. 15. Inspect and clean manifold. INSTALLATION 1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 2. Install generator. NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. Replace if necessary. 3. Using new gasket attach crossover pipe to exhaust manifold and tighten bolts to 54 Nm (40 ft. lbs.) and connect oxygen sensor lead. 4. Install EGR Tube and Generator/Power Steering Strut. 5. Using new gaskets install front exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 6. Attach exhaust crossover with a new gasket and tighten fasteners to 54 Nm (40 ft. lbs.). 7. Connect up stream oxygen sensor connector. 8. Install exhaust system. 9. Attach exhaust pipe to exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch lbs.). 10. Connect down stream oxygen sensor connector 11. Install front manifold heat shield and tighten attaching screws to 12 Nm (105 inch lbs.). 12. Install accessory drive belt. Refer to Accessory Drive section located in Engine for procedure. 13. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Removal and Installation > Page 2243 Exhaust Manifold: Service and Repair Cleaning and Inspection INSPECTION Check Exhaust Manifold Mounting Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust cross-over mounting surface with a straightedge and thickness gauge. CLEANING Remove the gasket material from the manifold surfaces (if equipped). Be careful not to gouge or scratch the sealing surface. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Band Clamp (Torca) Fastener ............................................................................................................. ...................................................... 75 Nm (55 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Specifications Exhaust Pipe/Muffler Hanger: Specifications Support Clamp Fastener ..................................................................................................................... ................................................. 17 Nm (150 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Bolts ..................................................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Fasteners ......................................................... ..................................................................................................................................... 12 Nm (105 inch lbs.) Muffler Fastener ................................................................................................................... ................................................................... 2 Nm (23 inch lbs.) Toe Board Fastener ......................... ........................................................................................................................................................ 2 Nm (23 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2253 Heat Shield: Description and Operation Heat Shields Heat shields are needed to protect both the vehicle and the floor pan from the high temperatures developed near the catalytic converter and muffler. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest for Muffler: > 11-05-98 > Apr > 98 > Muffler - Whistle Noise on Acceleration Muffler: Customer Interest Muffler - Whistle Noise on Acceleration NO: 11-05-98 GROUP: Exhaust DATE: Apr. 10, 1998 SUBJECT: Whistle Noise During Acceleration MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE AND SHORT WHEEL BASE (SWB) VEHICLES EQUIPPED WITH A 3.3L CALIFORNIA EMISSIONS (SALES CODE EGA/NAE) OR 3.8L CALIFORNIA EMISSIONS (SALES CODE EGH/NAE) ENGINE. SYMPTOM/CONDITION: Some vehicles may produce a high pitched whistle noise during Wide Open Throttle (WOT) acceleration with engine speeds above 2500 RPM. DIAGNOSIS: Drive the vehicle until reaching normal operating temperature. With all accessories turned off, listen for a high pitched whistle noise while accelerating at WOT with engine speeds above 2500 RPM. If a whistle noise is heard, check the air cleaner box cover for complete sealing. If no air cleaner box cover leaks are found, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04809149 Muffler, 3.0L LWB AR (1) 04809151 Muffler, 3.3L & 3.8L LWB AR (1) 04809152 Muffler, 3.3L & 3.8L SWB (Sales Code NAE) REPAIR PROCEDURE: This bulletin involves replacing the muffler. 1. Using the procedure outlined on page 11-4 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) replace the muffler. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-30-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 11-05-98 > Apr > 98 > Muffler - Whistle Noise on Acceleration Muffler: All Technical Service Bulletins Muffler - Whistle Noise on Acceleration NO: 11-05-98 GROUP: Exhaust DATE: Apr. 10, 1998 SUBJECT: Whistle Noise During Acceleration MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE AND SHORT WHEEL BASE (SWB) VEHICLES EQUIPPED WITH A 3.3L CALIFORNIA EMISSIONS (SALES CODE EGA/NAE) OR 3.8L CALIFORNIA EMISSIONS (SALES CODE EGH/NAE) ENGINE. SYMPTOM/CONDITION: Some vehicles may produce a high pitched whistle noise during Wide Open Throttle (WOT) acceleration with engine speeds above 2500 RPM. DIAGNOSIS: Drive the vehicle until reaching normal operating temperature. With all accessories turned off, listen for a high pitched whistle noise while accelerating at WOT with engine speeds above 2500 RPM. If a whistle noise is heard, check the air cleaner box cover for complete sealing. If no air cleaner box cover leaks are found, perform the Repair Procedure. PARTS REQUIRED: AR (1) 04809149 Muffler, 3.0L LWB AR (1) 04809151 Muffler, 3.3L & 3.8L LWB AR (1) 04809152 Muffler, 3.3L & 3.8L SWB (Sales Code NAE) REPAIR PROCEDURE: This bulletin involves replacing the muffler. 1. Using the procedure outlined on page 11-4 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) replace the muffler. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 11-30-01-93 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Page 2267 Muffler: Specifications Insulator Mounting Bracket on Muffler to Body Bolts ....................................................................................................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component Information > Specifications Exhaust Resonator: Specifications Insulator Mounting Bracket on Resonator to Body Bolts .................................................................................................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM - Auto Lamp DTC Diagnostics Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2280 Body Control Module Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 Body Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Body Control Module: Electrical Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Exterior Lighting (Park Lamps) Information Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 Instrument Cluster Interior Lighting Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 Power Door Locks W/Remote Keyless Entry (RKE) Power Door Locks W/O Remote Keyless Entry (RKE) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 Radio (CCD) Without Infinity Sound Radio (CCD) With Infinity Sound Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 Vehicle Communications Vehicle Theft Security System (VTSS) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 Windshield Wiper (Front) Windshield Wiper (Rear) Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 Body Control Module (Part 1 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Body Control Module (Part 2 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Body Control Module (Part 3 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Body Control Module (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 Body Control Module (Part 5 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 Body Control Module (Part 6 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Body Control Module (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following approved procedures is very important to the safety of individuals performing diagnostic tests. DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2321 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Servicing Sub-Assemblies Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced. DRBIII Safety Information WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: FUNCTION/INPUT LIMIT Volts 0 - 500 peak volts AC 0 - 500 volts DC Ohms (resistance)* 0-1.12 megohms Frequency Measured 0 - 10 kHz Frequency Generated 0 - 10 kHz Temperature -58 - 11000 F -50 - 600 C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ The circuit being tested must be protected by a 1OA fuse or circuit breaker. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code Body Control Module: Application and ID Body Code Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager Body Code = NS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code > Page 2324 Body Control Module: Application and ID Glossary of Terms ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The following terms are used interchangeably: - Left Front (LF) Door & Driver (DR) Door - Right Front (RF) Door and Passenger (PASS) Door - "Gage" and "Gauge" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2327 Body Control Module: Description and Operation Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2328 Body Control Module: Description and Operation Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2329 Body Control Module: Description and Operation Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2330 Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2331 - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Compass Mini-Trip Computer (CMTC) The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Auto Headlamps On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless Entry (RKE) actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off the exterior lamps as described above. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Headlamp Time Delay The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body. Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. Identification of System Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2332 The vehicle systems that are part of the "body" system are: - airbag system - chimes - compass/mini-trip - courtesy lamps I panel dimming - headlamp time delay - illuminated entry - radio (CCD) - information center - mechanical instrument cluster (MIC) - power door locks - remote keyless entry (RKE) - vehicle communications - vehicle theft security system (VTSS) - wipers Vehicles equipped with the highline body control module can be identified by the presence of the vehicle theft security system (VTSS). Vehicles with the midline body control module may have a compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or illuminated entry. Vehicles with a base body control module will not have any of these features. Introduction Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover all the necessary requirements to begin a logical diagnostic path for each repair. If there is a trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are used to direct you alphabetically to the specific systems. NOTE: The following terms are used interchangeably: Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door Mechanical Instrument Cluster (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. Power Door Lock System When the body control module (BCM) receives an input for a lock request (door lock switch, RKE, or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power door lock features: Sliding Door Memory Lock When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay as described above, and will turn it on again when all sliding doors are closed. NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2333 RKE (Remote Keyless Entry) Interface The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Radio System There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2334 been activated. System Self-Test NOTE: System self-test can be entered only with the DRB. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Shipping Mode By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle. The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation System Coverage These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth Voyager vehicles equipped with either base, midline, or highline body control modules. Airbag Trouble Code Descriptions Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in the airbag section to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with "AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes An airbag trouble code becomes active and stored as soon as it is detected with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2335 malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire harness and connectors. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal Diagnostic 2 - AECM Internal Diagnostic 1 - AECM Output Driver - AECM Stored Energy - Internal Diagnostic 3 - Incorrect AECM For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - No CCD Communication - Driver Squib Circuit Shorted - Passenger Squib Circuit Open - Driver Squib Term Shorted to Battery - Passenger Squib Circuit Shorted - Driver Squib Term Shorted to Ground - Pass Squib Term Shorted to Battery - Loss of Ignition Run Only - Pass Squib Term Short to Ground - Loss of Ignition Run/Start - Warning Lamp Circuit Open - Output Driver Not Tested - Warning Lamp Circuit Shorted Driver Squib Circuit Open NAME OF CODE Driver Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring open or high resistance in clockspring - Driver side airbag module open - Driver airbag line 1 or line 2 open - Loose or poor connection at connector terminals Driver Squib Circuit Shorted NAME OF CODE Driver Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring short - Driver side airbag module short Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2336 - Driver airbag line 1 shorted to line 2 - Loose, or poor connector not completely connected Driver Squib Term Shorted to Battery NAME OF CODE Driver Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to voltage - Driver airbag line 2 short to voltage - Faulty clockspring - Faulty airbag control module Driver Squib Term Shorted to Ground NAME OF CODE Driver Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to ground potential - Driver airbag line 2 short to ground potential - Faulty clockspring - Faulty airbag control module Loss of Ignition Run Only NAME OF CODE Loss of Ignition Run Only NOTE: This code becomes active as soon as the condition is detected (this is not a stored code). WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Open ignition run circuit - Open fuse - Ignition run circuit short to ground - Loose or poor connection at connector terminals Loss of Ignition Run/Start NAME OF CODE Loss of Ignition Run/Start NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2337 - Open ignition run/start circuit - Open fuse - Ignition run/start circuit short to ground - Loose or poor connection at connector terminals Passenger Squib Circuit Open NAME OF CODE Passenger Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) open - Passenger airbag line 1 or line 2 open - Loose or poor connection at connector terminals Passenger Squib Circuit Shorted NAME OF CODE Passenger Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) short - Passenger airbag line 1 shorted to line 2 - Loose or poor connection at connector terminals Pass Squib Term Shorted to Battery NAME OF CODE Pass Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to voltage - Passenger airbag line 2 short to voltage - Faulty airbag control module Pass Squib Term Shorted to Ground NAME OF CODE Pass Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to ground potential Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2338 - Passenger airbag line 2 short to ground potential - Faulty airbag control module Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NAME OF CODE Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or during a lamp check. SET CONDITION With the voltage on, the airbag warning lamp driver circuit is other than expected. POSSIBLE CAUSES - Faulty warning lamp - Open fused ignition switch output circuit to Information Center - Airbag warning lamp driver circuit short to ground - Airbag warning lamp driver circuit short to voltage - Faulty information center printed circuit board - Loose or poor connection at connector terminal Output Driver Not Tested NAME OF CODE Output Driver Not Tested WHEN MONITORED At ignition on. SET CONDITION This code may set whenever another code is set due to any short to battery or short to ground failure of the squib circuits. If all other squib codes have been repaired and this code appears active by itself, the problem will be an internal failure of the airbag control module. POSSIBLE CAUSES - Short circuit to ground or to battery in either driver or passenger airbag lines - Defective airbag control module Trouble Code Testing Notes Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes. It is not necessary to perform all of the tests to diagnose an individual code. The body control module will set a diagnostic trouble code if a monitored input is determined to be malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the trouble code condition is removed, the body control module will back out the diagnostic trouble code if the trouble code condition remains cleared for twenty ignition cycles. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This will direct you to the specific test(s) that must be performed. ASB Message Not Received NAME OF CODE ASB Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from CAB every second. If this message is not received by the BCM for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from CAB to BCM Airbag Message Not Received Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2339 NAME OF CODE Airbag Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from ACM every second. It this message is not received by the BCM for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from ACM to BCM Battery Power to Module Disconnected NAME OF CODE Battery Power to Module Disconnected WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION Battery power to the BCM is disconnected while the ignition is on. THEORY OF OPERATION The body control module checks battery input and determines if the battery is connected. POSSIBLE CAUSES - In shipping mode - IOD fuse missing - Open wire - Blown IOD fuse EATX PRNDL Message Test Failed NAME OF CODE EATX PRNDL Message Test Failed WHEN MONITORED When engine is running. SET CONDITION The engine is running above 450 rpm and the body control module has not received a transmission PRNDL message. THEORY OF OPERATION The body control module will monitor the CCD bus and look for the transmission PRNDL message whenever the engine rpm is above 450. POSSIBLE CAUSES - Body Control module - Transmission control module - CCD bus failure - Loss of power to transmission control module EEPROM Checksum Failure NAME OF CODE EEPROM Checksum Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The sum of EEPROM constants does not equal the correct value. THEORY OF OPERATION By using a checksum, the BCM monitors the value of each programmable constant. The code is set if any value is incorrect. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2340 - Body Control module Front Wiper Park Switch CKT Open NAME OF CODE Front Wiper Park Switch Ckt Open WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Open wire - Wiper motor - Body Control module Front Wiper Park Switch CKT-Shorted NAME OF CODE Front Wiper Park Switch Ckt-Shorted WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Shorted wire - Wiper motor - Body Control module Fuel Level Sending Circuit Error NAME OF CODE Fuel Level Sending Circuit Error WHEN MONITORED With the ignition key on and battery voltage above 10 volts. SET CONDITION When the BCM senses an open or short on the fuel level sensor signal circuit. THEORY OF OPERATION The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be set. POSSIBLE CAUSES - Open wire - Shorted wire - Fuel level sending unit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2341 - Body control module Internal Module Test Failed NAME OF CODE Internal Module Test Failed WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The body control module performs an internal check and determines the body control module is not functioning properly. THEORY OF OPERATION The body control module performs internal diagnostics on demand and determines if the body control module microprocessor is functioning properly. POSSIBLE CAUSES - Body control module Left Door Key CYL Arm SW Failure NAME OF CODE Left Door key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Key CYL Disarm SW Failure NAME OF CODE Left Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Lock Switch Failure NAME OF CODE Left Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2342 SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Left Door Unlock Switch Failure NAME OF CODE Left Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Liftgate Key CYL Arm SW Failure NAME OF CODE Liftgate Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Key CYL Disarm SW Failure NAME OF CODE Liftgate Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2343 level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Door Mux CKT Short to GND NAME OF CODE Liftgate Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (Liftgate Switch MUX) - Body control module LT Front Door Mux Circuit Short to GND NAME OF CODE LT Front Door MUX Circuit Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (LF Door Switch MUX) - Body control module No CCD Message From PCM NAME OF CODE No CCD Message From PCM WHEN MONITORED When the ignition is in the run or start position and battery voltage is above 10 volts. SET CONDITION The BCM looks for engine messages over the CCD bus and does not receive a message within a 2-second period. THEORY OF OPERATION The body control module will monitor the engine messages after the ignition has been turned on. POSSIBLE CAUSES - Body control module - Powertrain control module - CCD Bus failure Rear Wiper Mux Circuit Error NAME OF CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2344 Rear Wiper MUX Circuit Error WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts. SET CONDITION When the rear wiper MUX circuit senses a voltage above 5.0 volts. THEORY OF OPERATION The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level. The voltage level will determine the wiper function to be performed. That level will be below 5.0 volts. POSSIBLE CAUSES - Circuit shorted to battery - Open CCM ground circuit Right Door Key CYL Arm SW Failure NAME OF CODE Right Door Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Key CYL Disarm SW Failure NAME OF CODE Right Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Lock Switch Failure NAME OF CODE Right Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2345 THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module Right Door Unlock Switch Failure NAME OF CODE Right Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module RT Front Door Mux CKT Short to GND NAME OF CODE RT Front Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below .4 volts on the RF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (RF Door Switch MUX) - Body control module Horn Switch Failure NAME OF CODE Horn Switch Failure WHEN MONITORED Continuously with battery connected and IOD fuse installed. SET CONDITION The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to cool down. POSSIBLE CAUSES - Shorted horn relay control circuit - Defective horn switch - Defective BCM Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2346 CCD Radio NAME OF CODE CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume Down Switch (Stuck) Preset Switch (Stuck) WHEN MONITORED Anytime ignition is on and voltage is above 10.0 volts. SET CONDITION When a switch is held active for longer than 20 seconds. THEORY OF OPERATION The BCM monitors the control switches for an active condition and performs the required radio function. When a switch is active for longer than 10 seconds, that switch function will be disabled until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be set. POSSIBLE CAUSES - Defective remote control switch - Shorted radio control MUX circuit Vehicle Communication The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2347 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Wiper System FRONT The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned off, the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. REAR The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics SELF DIAGNOSTIC TEST To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about five seconds) then release the buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarily appear. INSTRUMENT CLUSTER DTC CHART DTC ..................................................................................................................................................... .................................................... Description 110 ............................................................................... .......................................................................................................... Memory Fault in cluster 111 ..... .............................................................................................................................................................. ................... Calibration fault in cluster 905 ......................................................................................... ................................................................................ No CCD bus messages from TCM 921 .............. .............................................................................................................................................................. ......... Odometer fault from BCM 940 ................................................................................................... ...................................................................... No CCD bus messages from PCM 999 ........................ .............................................................................................................................................................. .................... End of Codes NOTE: For DTC testing see Condition Diagnostic Charts below. CONDITIONS Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis - Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis - Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis - Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis - Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis - Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis - Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21) CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). CLUSTER CALIBRATION TABLE Speedometer ....................................................................................................................................... ................................................. Calibration Point 1 ........................................................................................................................................................... ............................................... 0 mph (0 Km/h) 2 ................................................................................. ..................................................................................................................... 20 mph (40 Km/h) 3 ....... .............................................................................................................................................................. ................................. 55 mph (80 Km/h) 4 ........................................................................................... .......................................................................................................... 75 mph(120 Km/h) Tachometer ......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ............................................................... 0 rpm 2 ................................................................................ .................................................................................................................................... 1000 rpm 3 ..... .............................................................................................................................................................. ................................................. 3000 rpm 4 ........................................................................................ ............................................................................................................................ 6000 rpm Fuel Gauge .......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ......................................................... Empty(E) 2 ................................................................................. ................................................................................................................................... 1/8 Filled 3 ....... .............................................................................................................................................................. ............................................... 1/4 Filled 4 ........................................................................................... ............................................................................................................................ Full (F) Temperature Gauge ............................................................................................................................ ............................................... Calibration Point 1 ........................................................................................................................................................... .......................................................... Cold (C) 2 ................................................................................. .............................................................................................................................. Low Normal 3 ....... .............................................................................................................................................................. ......................................... High Normal 4 ............................................................................................ ........................................................................................................................... Hot (H) DIM TEST When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2350 no change, a problem exists in the cluster. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2351 Body Control Module: Scan Tool Testing and Procedures Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions. DRBIII Error Messages Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the scantool manufacturer for information and assistance. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2352 Body Control Module: Service and Repair Body Control Module Location REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4. Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION 1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5. Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker reinforcement. 8. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2353 Body Control Module: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge (0-300 psi) - Test Light - Voltmeter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Fig 1 Powertrain Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Powertrain Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2381 Powertrain Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2382 Powertrain Control Module: Description and Operation Fig 1 Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Head Pressure - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Heated Oxygen Sensors (Upstream and Downstream) - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - SCI Receive - Speed Control System Controls - Throttle Position Sensor - Transaxle Park/Neutral Position Switch (automatic transaxle) - Transmission Control Module - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay - Automatic Shutdown (ASD) Relay - Data Link Connector - Electric EGR Transducer - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coil - Leak Detection Pump - Malfunction Indicator (Check Engine) Lamp - Proportional Purge Solenoid - Radiator Fan Control Module - Speed Control Solenoids - Tachometer Output - Torque Converter Clutch Solenoid (3 speed transmission) - Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2383 Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage - Engine coolant temperature - Exhaust gas content (oxygen sensors) - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs: Barometric pressure - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs: Air conditioning select switch head pressure - Brake switch - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) - Vehicle distance (speed) Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump. PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute pressure sensor, throttle position sensor and engine coolant temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2384 Powertrain Control Module: Service and Repair Fig 29 Power Distribution Center Retaining Screws REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29). Fig 30 Battery Heat Shield 3. Remove heat shield from battery (Fig 30). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2385 Fig 31 Battery Clamp 4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle. Fig 32 PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2386 Fig 33 PCM 40 Way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33). Remove both way connectors. Fig 34 PCM Removal/Installation 9. Remove 3 screws holding PCM to fender (Fig. 34). 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2387 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2412 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2415 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2420 Fuel Pump Relay: Diagrams Fuel Pump Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2421 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2422 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2428 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2429 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2430 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2431 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2432 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2433 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2434 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2435 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2436 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2437 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2438 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2439 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2440 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2441 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2442 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2443 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2444 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2445 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 2447 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2450 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2460 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2461 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2464 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2465 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2466 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2467 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2468 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2469 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2470 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2471 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2472 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2473 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2474 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2475 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2476 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2477 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2478 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2479 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2480 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2481 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2484 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2485 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2486 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2487 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2488 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2492 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2493 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2494 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2495 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2496 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2500 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2503 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2504 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2505 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2506 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2507 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2508 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2509 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2510 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2511 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2512 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2513 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2514 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2515 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2516 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2517 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2518 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2519 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2523 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2524 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2525 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2526 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Tank Sending Unit Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2533 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2534 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2535 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2536 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor ........................................................................................................................................ .......................................................... 4 Nm (35 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2540 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2541 Map Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2542 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2543 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 92 Map Sensor Connector NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3 (Fig. 92). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (4.5 to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2544 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 9 MAP Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake manifold (Fig. 9). 3. Remove sensor from manifold. INSTALLATION - Reverse the above procedure for installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 2549 Oxygen Sensor: Mechanical Specifications Upstream 02S ...................................................................................................................................... ......................................................... 27 Nm (20 ft lb) Downstream 02S ................................................................................................................................. ......................................................... 27 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Oxygen Sensor Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2552 Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector > Page 2555 Downstream Heated Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2556 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2557 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 2560 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 2561 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground. - The white wires in the sensor connector are the power and ground circuits for the heater. - Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. 3. Resistance should be between 4 and 7 ohms. - If not replace the sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement Fig 122 Oxygen Sensor Grommet Cover WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122). Fig 123 Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123). Fig 124 Oxygen Sensor Removal & Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2564 - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 2565 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Fig 121 Upstream Heated Oxygen Sensor The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121). CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2570 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2571 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2572 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2573 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2574 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2575 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2584 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2585 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2586 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2592 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2593 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2598 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2599 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2600 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2606 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 2607 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2610 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2611 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2612 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2613 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2614 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2615 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2634 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2635 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2636 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2637 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2638 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM) transmits the vehicle speed signal to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 2641 Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor. CIRCUIT OPERATION The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that information to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 2642 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical OPERATION The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The speed and distance signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired MAP value. - Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine speed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 2643 Vehicle Speed Sensor: Testing and Inspection For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2648 Fuel Low Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2652 Fuel Temperature Sensor Connector CNG Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 2657 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2658 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2659 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2660 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2661 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2662 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2668 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2669 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2674 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2684 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2685 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2686 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2687 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2688 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2689 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2690 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2691 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2692 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2693 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2694 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2695 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2696 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2700 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2723 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2724 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2725 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2726 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 2736 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 2742 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 2743 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 2744 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2748 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2749 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2750 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2751 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 2758 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2765 Idle Speed: Testing and Inspection THROTTLE BODY MINIMUM AIR FLOW CHECK Fig 97 Air Metering Fitting 6457 Fig 100 PCV Valve 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457 (0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link connector. 10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. 2.4L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 500-875 RPM Above 1000 Miles 550-875 RPM 3.0L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 560-910 RPM Above 1000 Miles 610-910 RPM 3.3L/3.8L Idle Specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2766 Odometer Reading Idle RPM Below 1000 Miles 525-875 RPM Above 1000 Miles 575-875 RPM 14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle purge line. 18. Remove DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig 125 Air Inlet Resonator REMOVAL 1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner housing halves together. Fig 126 Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing (Fig. 126). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2771 Fig 127 Air Cleaner Element 4. Remove element from air cleaner housing (Fig. 127). INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 2777 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 2791 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". PURPOSE Transfer electrical current from the coil to the individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. CONSTRUCTION The spark plug cables and spark plug boots are made from high temperature silicone materials. Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. - The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. - They also identify proper heat shield installation on the boot for service. - All spark plug cable leads are properly identified with cylinder numbers. Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure. - Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. - Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. - The bottom of the spark plug heat shield must make contact with the spark plug hex. Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Service Life Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions. CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2794 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. - Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil pack and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. Secondary Ignition Cable Resistance Test Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables Ignition Cable: Service and Repair Replacing Cables Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. CAUTIONS: - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. - Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. - Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. SPARK PLUG CABLES #3 AND #5 Removal 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. - Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the retaining bracket. - Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. SPARK PLUG CABLE #1 Removal 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 5. Wipe spark plug insulator clean with a dry cloth before installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 2797 6. Remove the cable from the retaining bracket. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt, refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 2798 Ignition Cable: Service and Repair Cleaning Cables Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2802 Spark Plug: Service Precautions CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2803 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2804 Spark Plug: Description and Operation Fig 3 Platinum Plug Pads NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions. The recommended service life under severe conditions is 75,000 miles. - A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3). - Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's original spark plugs that have been determined good. - Do not apply anti-seize compound to new spark plugs. NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti-seize compound does not make contact with the spark plug electrodes or ceramic insulator. Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the procedures. Due to the engine packaging environment for this engine, extreme care should be used when installing the spark plugs to avoid cross threading problems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2807 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2808 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2809 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2810 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2811 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2812 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2813 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: - In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2814 Spark Plug: Adjustments Setting Spark Plug Gap - Typical Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2815 Spark Plug: Service and Repair Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. CAUTIONS: - Use extreme care when removing and installing the spark plug cables. - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. SPARK PLUG #3 AND #5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. SPARK PLUG #1 REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Testing and Inspection > Page 2816 insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt, refer to Cooling System. OTHER PLUGS REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Ratio .............................................................................................................................. ........................................................................... 8.9:1 Minimum Compression ................................... ........................................................................................................................................ 689.5 kPa (100 psi) Maximum Variation Between Cylinders ................................................................................ ......................................................................................... 25% Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2820 Compression Check: Testing and Inspection The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire (Conventional Ignition System). For Direct Ignition System (DIS) disconnect the coil connector. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is reached on gage. Record this pressure as #1 cylinder pressure. 7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than (689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt drives. 18. Road test vehicle as a final test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications This engine is equipped with hydraulic valve lifters and are not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations A/C Pressure Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations > Page 2828 A/C Pressure Switch Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Locations > Page 2829 A/C Signal: Description and Operation PURPOSE Powertrain Control Module (PCM) monitors engine load and A/C system pressure, and cycles the A/C compressor clutch accordingly. CONDITIONS A/C or Defrost switch ON. Combination valve, A/C low pressure and high pressure switches are closed. OPERATION Powertrain Control Module (PCM) receives an A/C selected signal. - PCM engages A/C compressor clutch (by grounding clutch relay). - PCM cycles compressor clutch depending on engine load and A/C system pressure. - PCM maintains correct engine idle speed, through the Idle Air Control (IAC) Motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM - Auto Lamp DTC Diagnostics Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2839 Body Control Module Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Body Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Body Control Module: Electrical Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Exterior Lighting (Park Lamps) Information Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Instrument Cluster Interior Lighting Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Power Door Locks W/Remote Keyless Entry (RKE) Power Door Locks W/O Remote Keyless Entry (RKE) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Radio (CCD) Without Infinity Sound Radio (CCD) With Infinity Sound Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Vehicle Communications Vehicle Theft Security System (VTSS) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Windshield Wiper (Front) Windshield Wiper (Rear) Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Body Control Module (Part 1 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Body Control Module (Part 2 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 Body Control Module (Part 3 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 Body Control Module (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Body Control Module (Part 5 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Body Control Module (Part 6 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 Body Control Module (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following approved procedures is very important to the safety of individuals performing diagnostic tests. DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2880 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Servicing Sub-Assemblies Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced. DRBIII Safety Information WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: FUNCTION/INPUT LIMIT Volts 0 - 500 peak volts AC 0 - 500 volts DC Ohms (resistance)* 0-1.12 megohms Frequency Measured 0 - 10 kHz Frequency Generated 0 - 10 kHz Temperature -58 - 11000 F -50 - 600 C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ The circuit being tested must be protected by a 1OA fuse or circuit breaker. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code Body Control Module: Application and ID Body Code Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager Body Code = NS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code > Page 2883 Body Control Module: Application and ID Glossary of Terms ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The following terms are used interchangeably: - Left Front (LF) Door & Driver (DR) Door - Right Front (RF) Door and Passenger (PASS) Door - "Gage" and "Gauge" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2886 Body Control Module: Description and Operation Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2887 Body Control Module: Description and Operation Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2888 Body Control Module: Description and Operation Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2889 Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2890 - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Compass Mini-Trip Computer (CMTC) The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Auto Headlamps On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless Entry (RKE) actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off the exterior lamps as described above. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Headlamp Time Delay The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body. Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. Identification of System Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2891 The vehicle systems that are part of the "body" system are: - airbag system - chimes - compass/mini-trip - courtesy lamps I panel dimming - headlamp time delay - illuminated entry - radio (CCD) - information center - mechanical instrument cluster (MIC) - power door locks - remote keyless entry (RKE) - vehicle communications - vehicle theft security system (VTSS) - wipers Vehicles equipped with the highline body control module can be identified by the presence of the vehicle theft security system (VTSS). Vehicles with the midline body control module may have a compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or illuminated entry. Vehicles with a base body control module will not have any of these features. Introduction Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover all the necessary requirements to begin a logical diagnostic path for each repair. If there is a trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are used to direct you alphabetically to the specific systems. NOTE: The following terms are used interchangeably: Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door Mechanical Instrument Cluster (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. Power Door Lock System When the body control module (BCM) receives an input for a lock request (door lock switch, RKE, or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power door lock features: Sliding Door Memory Lock When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay as described above, and will turn it on again when all sliding doors are closed. NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2892 RKE (Remote Keyless Entry) Interface The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Radio System There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2893 been activated. System Self-Test NOTE: System self-test can be entered only with the DRB. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Shipping Mode By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle. The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation System Coverage These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth Voyager vehicles equipped with either base, midline, or highline body control modules. Airbag Trouble Code Descriptions Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in the airbag section to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with "AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes An airbag trouble code becomes active and stored as soon as it is detected with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2894 malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire harness and connectors. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal Diagnostic 2 - AECM Internal Diagnostic 1 - AECM Output Driver - AECM Stored Energy - Internal Diagnostic 3 - Incorrect AECM For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - No CCD Communication - Driver Squib Circuit Shorted - Passenger Squib Circuit Open - Driver Squib Term Shorted to Battery - Passenger Squib Circuit Shorted - Driver Squib Term Shorted to Ground - Pass Squib Term Shorted to Battery - Loss of Ignition Run Only - Pass Squib Term Short to Ground - Loss of Ignition Run/Start - Warning Lamp Circuit Open - Output Driver Not Tested - Warning Lamp Circuit Shorted Driver Squib Circuit Open NAME OF CODE Driver Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring open or high resistance in clockspring - Driver side airbag module open - Driver airbag line 1 or line 2 open - Loose or poor connection at connector terminals Driver Squib Circuit Shorted NAME OF CODE Driver Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring short - Driver side airbag module short Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2895 - Driver airbag line 1 shorted to line 2 - Loose, or poor connector not completely connected Driver Squib Term Shorted to Battery NAME OF CODE Driver Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to voltage - Driver airbag line 2 short to voltage - Faulty clockspring - Faulty airbag control module Driver Squib Term Shorted to Ground NAME OF CODE Driver Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to ground potential - Driver airbag line 2 short to ground potential - Faulty clockspring - Faulty airbag control module Loss of Ignition Run Only NAME OF CODE Loss of Ignition Run Only NOTE: This code becomes active as soon as the condition is detected (this is not a stored code). WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Open ignition run circuit - Open fuse - Ignition run circuit short to ground - Loose or poor connection at connector terminals Loss of Ignition Run/Start NAME OF CODE Loss of Ignition Run/Start NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2896 - Open ignition run/start circuit - Open fuse - Ignition run/start circuit short to ground - Loose or poor connection at connector terminals Passenger Squib Circuit Open NAME OF CODE Passenger Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) open - Passenger airbag line 1 or line 2 open - Loose or poor connection at connector terminals Passenger Squib Circuit Shorted NAME OF CODE Passenger Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) short - Passenger airbag line 1 shorted to line 2 - Loose or poor connection at connector terminals Pass Squib Term Shorted to Battery NAME OF CODE Pass Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to voltage - Passenger airbag line 2 short to voltage - Faulty airbag control module Pass Squib Term Shorted to Ground NAME OF CODE Pass Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to ground potential Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2897 - Passenger airbag line 2 short to ground potential - Faulty airbag control module Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NAME OF CODE Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or during a lamp check. SET CONDITION With the voltage on, the airbag warning lamp driver circuit is other than expected. POSSIBLE CAUSES - Faulty warning lamp - Open fused ignition switch output circuit to Information Center - Airbag warning lamp driver circuit short to ground - Airbag warning lamp driver circuit short to voltage - Faulty information center printed circuit board - Loose or poor connection at connector terminal Output Driver Not Tested NAME OF CODE Output Driver Not Tested WHEN MONITORED At ignition on. SET CONDITION This code may set whenever another code is set due to any short to battery or short to ground failure of the squib circuits. If all other squib codes have been repaired and this code appears active by itself, the problem will be an internal failure of the airbag control module. POSSIBLE CAUSES - Short circuit to ground or to battery in either driver or passenger airbag lines - Defective airbag control module Trouble Code Testing Notes Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes. It is not necessary to perform all of the tests to diagnose an individual code. The body control module will set a diagnostic trouble code if a monitored input is determined to be malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the trouble code condition is removed, the body control module will back out the diagnostic trouble code if the trouble code condition remains cleared for twenty ignition cycles. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This will direct you to the specific test(s) that must be performed. ASB Message Not Received NAME OF CODE ASB Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from CAB every second. If this message is not received by the BCM for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from CAB to BCM Airbag Message Not Received Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2898 NAME OF CODE Airbag Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from ACM every second. It this message is not received by the BCM for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from ACM to BCM Battery Power to Module Disconnected NAME OF CODE Battery Power to Module Disconnected WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION Battery power to the BCM is disconnected while the ignition is on. THEORY OF OPERATION The body control module checks battery input and determines if the battery is connected. POSSIBLE CAUSES - In shipping mode - IOD fuse missing - Open wire - Blown IOD fuse EATX PRNDL Message Test Failed NAME OF CODE EATX PRNDL Message Test Failed WHEN MONITORED When engine is running. SET CONDITION The engine is running above 450 rpm and the body control module has not received a transmission PRNDL message. THEORY OF OPERATION The body control module will monitor the CCD bus and look for the transmission PRNDL message whenever the engine rpm is above 450. POSSIBLE CAUSES - Body Control module - Transmission control module - CCD bus failure - Loss of power to transmission control module EEPROM Checksum Failure NAME OF CODE EEPROM Checksum Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The sum of EEPROM constants does not equal the correct value. THEORY OF OPERATION By using a checksum, the BCM monitors the value of each programmable constant. The code is set if any value is incorrect. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2899 - Body Control module Front Wiper Park Switch CKT Open NAME OF CODE Front Wiper Park Switch Ckt Open WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Open wire - Wiper motor - Body Control module Front Wiper Park Switch CKT-Shorted NAME OF CODE Front Wiper Park Switch Ckt-Shorted WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Shorted wire - Wiper motor - Body Control module Fuel Level Sending Circuit Error NAME OF CODE Fuel Level Sending Circuit Error WHEN MONITORED With the ignition key on and battery voltage above 10 volts. SET CONDITION When the BCM senses an open or short on the fuel level sensor signal circuit. THEORY OF OPERATION The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be set. POSSIBLE CAUSES - Open wire - Shorted wire - Fuel level sending unit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2900 - Body control module Internal Module Test Failed NAME OF CODE Internal Module Test Failed WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The body control module performs an internal check and determines the body control module is not functioning properly. THEORY OF OPERATION The body control module performs internal diagnostics on demand and determines if the body control module microprocessor is functioning properly. POSSIBLE CAUSES - Body control module Left Door Key CYL Arm SW Failure NAME OF CODE Left Door key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Key CYL Disarm SW Failure NAME OF CODE Left Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Lock Switch Failure NAME OF CODE Left Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2901 SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Left Door Unlock Switch Failure NAME OF CODE Left Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Liftgate Key CYL Arm SW Failure NAME OF CODE Liftgate Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Key CYL Disarm SW Failure NAME OF CODE Liftgate Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2902 level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Door Mux CKT Short to GND NAME OF CODE Liftgate Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (Liftgate Switch MUX) - Body control module LT Front Door Mux Circuit Short to GND NAME OF CODE LT Front Door MUX Circuit Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (LF Door Switch MUX) - Body control module No CCD Message From PCM NAME OF CODE No CCD Message From PCM WHEN MONITORED When the ignition is in the run or start position and battery voltage is above 10 volts. SET CONDITION The BCM looks for engine messages over the CCD bus and does not receive a message within a 2-second period. THEORY OF OPERATION The body control module will monitor the engine messages after the ignition has been turned on. POSSIBLE CAUSES - Body control module - Powertrain control module - CCD Bus failure Rear Wiper Mux Circuit Error NAME OF CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2903 Rear Wiper MUX Circuit Error WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts. SET CONDITION When the rear wiper MUX circuit senses a voltage above 5.0 volts. THEORY OF OPERATION The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level. The voltage level will determine the wiper function to be performed. That level will be below 5.0 volts. POSSIBLE CAUSES - Circuit shorted to battery - Open CCM ground circuit Right Door Key CYL Arm SW Failure NAME OF CODE Right Door Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Key CYL Disarm SW Failure NAME OF CODE Right Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Lock Switch Failure NAME OF CODE Right Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2904 THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module Right Door Unlock Switch Failure NAME OF CODE Right Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module RT Front Door Mux CKT Short to GND NAME OF CODE RT Front Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below .4 volts on the RF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (RF Door Switch MUX) - Body control module Horn Switch Failure NAME OF CODE Horn Switch Failure WHEN MONITORED Continuously with battery connected and IOD fuse installed. SET CONDITION The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to cool down. POSSIBLE CAUSES - Shorted horn relay control circuit - Defective horn switch - Defective BCM Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2905 CCD Radio NAME OF CODE CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume Down Switch (Stuck) Preset Switch (Stuck) WHEN MONITORED Anytime ignition is on and voltage is above 10.0 volts. SET CONDITION When a switch is held active for longer than 20 seconds. THEORY OF OPERATION The BCM monitors the control switches for an active condition and performs the required radio function. When a switch is active for longer than 10 seconds, that switch function will be disabled until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be set. POSSIBLE CAUSES - Defective remote control switch - Shorted radio control MUX circuit Vehicle Communication The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 2906 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Wiper System FRONT The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned off, the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. REAR The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics SELF DIAGNOSTIC TEST To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about five seconds) then release the buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarily appear. INSTRUMENT CLUSTER DTC CHART DTC ..................................................................................................................................................... .................................................... Description 110 ............................................................................... .......................................................................................................... Memory Fault in cluster 111 ..... .............................................................................................................................................................. ................... Calibration fault in cluster 905 ......................................................................................... ................................................................................ No CCD bus messages from TCM 921 .............. .............................................................................................................................................................. ......... Odometer fault from BCM 940 ................................................................................................... ...................................................................... No CCD bus messages from PCM 999 ........................ .............................................................................................................................................................. .................... End of Codes NOTE: For DTC testing see Condition Diagnostic Charts below. CONDITIONS Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis - Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis - Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis - Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis - Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis - Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis - Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21) CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). CLUSTER CALIBRATION TABLE Speedometer ....................................................................................................................................... ................................................. Calibration Point 1 ........................................................................................................................................................... ............................................... 0 mph (0 Km/h) 2 ................................................................................. ..................................................................................................................... 20 mph (40 Km/h) 3 ....... .............................................................................................................................................................. ................................. 55 mph (80 Km/h) 4 ........................................................................................... .......................................................................................................... 75 mph(120 Km/h) Tachometer ......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ............................................................... 0 rpm 2 ................................................................................ .................................................................................................................................... 1000 rpm 3 ..... .............................................................................................................................................................. ................................................. 3000 rpm 4 ........................................................................................ ............................................................................................................................ 6000 rpm Fuel Gauge .......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ......................................................... Empty(E) 2 ................................................................................. ................................................................................................................................... 1/8 Filled 3 ....... .............................................................................................................................................................. ............................................... 1/4 Filled 4 ........................................................................................... ............................................................................................................................ Full (F) Temperature Gauge ............................................................................................................................ ............................................... Calibration Point 1 ........................................................................................................................................................... .......................................................... Cold (C) 2 ................................................................................. .............................................................................................................................. Low Normal 3 ....... .............................................................................................................................................................. ......................................... High Normal 4 ............................................................................................ ........................................................................................................................... Hot (H) DIM TEST When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2909 no change, a problem exists in the cluster. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2910 Body Control Module: Scan Tool Testing and Procedures Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions. DRBIII Error Messages Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the scantool manufacturer for information and assistance. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2911 Body Control Module: Service and Repair Body Control Module Location REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4. Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION 1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5. Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker reinforcement. 8. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 2912 Body Control Module: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge (0-300 psi) - Test Light - Voltmeter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation Brake Signal: Description and Operation LOCATION Sensor mounted on brake pedal support bracket. PURPOSE Powertrain Control Module (PCM) uses switch input to control idle speed and speed control. OPERATION PCM vents speed control system vacuum and turns speed control system OFF when appraised of a brake switch actuation. PCM prevents engine stall during rapid decel, by actuating Idle Air Control (IAC) motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2920 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 2921 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2924 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2925 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2926 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2927 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2928 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2929 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2930 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2931 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2932 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2933 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2934 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2935 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2936 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2937 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2938 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2939 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2940 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2941 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2942 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2943 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2944 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2945 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2946 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2947 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2948 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2952 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2953 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2954 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2955 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2956 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2960 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2963 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2964 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2965 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2966 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2969 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2970 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2971 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2972 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2973 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2974 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2975 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2977 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2978 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2979 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2980 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2981 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2982 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2983 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2984 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2985 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2986 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2990 Data Link Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector Data Link Connector: Description and Operation Data Link Connector CIRCUIT OPERATION Circuit M1 from fuse 10 in the Power Distribution Center (PDC) supplies battery voltage to the data link connector. A twisted pair of wires, circuits D1 and D2 connect the data link connector to the CCD Bus. Ground circuit Z11 splices to the data link connector. Circuit Z11 splices to circuit Z12. Both circuit connect to the PCM. Circuit Z2 also connects to the data link connector. Circuit D20 connects to cavity 75 of the PCM. Circuit D20 is the SCI receive circuit for the PCM. Circuit D21 connects to cavity 65 of the PCM. Circuit D21 is the SCI transmit circuit for the PCM. The D21 circuit splices to the Transmission Control Module (TCM). The D6 circuit also connects between the data link connector and the TCM. Helpful Information Circuit Z12 also supplies ground for the PCM high current drivers and has the same termination point as circuit Z11. If the system loses ground for circuits Z11 and Z12, the vehicle will not operate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector > Page 2993 Data Link Connector: Description and Operation SCI Receive The SCI receive circuit is used as a communication path for the scan tool. The scan tool receives data through this circuit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector > Page 2994 Data Link Connector: Description and Operation SCI Transmit PURPOSE Powertrain Control Module (PCM) sends data to the scan tool through this circuit, including; - Sensor input values - Diagnostic Trouble Codes (DTC's) stored in memory - Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or no crank sensor signal). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations EGR Backpressure Transducer: Locations EGR Solenoid And Valve Electric EGR Transducer (EET) EGR System Mounted near the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 2998 EGR Backpressure Transducer: Description and Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve varies with the backpressure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 2999 EGR Backpressure Transducer: Testing and Inspection TESTING ELECTRICAL SOLENOID PORTION OF VALVE This is not to be used as a complete test of the EGR system. Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly Fig 4 EGR System TESTING VACUUM TRANSDUCER PORTION OF VALVE NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve has ruptured or is leaking. The second part of the test will determine if engine vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used as a complete test of the EGR system. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to operating temperature. - Hold engine speed at approximately 1,500 rpm. 9. Check for steady engine vacuum (full-manifold) at this hose. 10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4) on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector (Fig. 4) at the valve control. - This will simulate an open circuit (no ground from the PCM) at the valve. 15. Start the engine and bring to operating temperature. 16. Hold the engine speed to approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. - It must be high enough to hold the bleed valve in the transducer portion of the valve closed. - Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 3000 vacuum gauge. - Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. 17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. - This low reading is normal. - At idle speed, the gauge reading will be erratic. - This is also normal. 18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Locations > Page 3001 EGR Backpressure Transducer: Service and Repair EGR Mounting REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for signs of leakage or cracks. INSTALLATION 1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and electrical connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Fig 1 Powertrain Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 Powertrain Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3029 Powertrain Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3030 Powertrain Control Module: Description and Operation Fig 1 Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Head Pressure - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Heated Oxygen Sensors (Upstream and Downstream) - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - SCI Receive - Speed Control System Controls - Throttle Position Sensor - Transaxle Park/Neutral Position Switch (automatic transaxle) - Transmission Control Module - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay - Automatic Shutdown (ASD) Relay - Data Link Connector - Electric EGR Transducer - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coil - Leak Detection Pump - Malfunction Indicator (Check Engine) Lamp - Proportional Purge Solenoid - Radiator Fan Control Module - Speed Control Solenoids - Tachometer Output - Torque Converter Clutch Solenoid (3 speed transmission) - Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3031 Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage - Engine coolant temperature - Exhaust gas content (oxygen sensors) - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs: Barometric pressure - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs: Air conditioning select switch head pressure - Brake switch - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) - Vehicle distance (speed) Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump. PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute pressure sensor, throttle position sensor and engine coolant temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3032 Powertrain Control Module: Service and Repair Fig 29 Power Distribution Center Retaining Screws REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29). Fig 30 Battery Heat Shield 3. Remove heat shield from battery (Fig 30). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3033 Fig 31 Battery Clamp 4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle. Fig 32 PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3034 Fig 33 PCM 40 Way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33). Remove both way connectors. Fig 34 PCM Removal/Installation 9. Remove 3 screws holding PCM to fender (Fig. 34). 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3035 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Tank Sending Unit Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor ........................................................................................................................... ....................................................... 2 Nm (18 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3044 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3064 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3065 Idle Air Control Moor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3066 Idle Air Control Motor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3067 Idle Speed/Throttle Actuator - Electronic: Description and Operation PURPOSE Maintains optimum idle speed under varying engine loads. Prevents deceleration die out. OPERATION Powertrain Control Module (PCM) calculates proper idle speed using information from throttle position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches. PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body. Prevents decel die out by increasing air flow when throttle is closed suddenly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3068 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool. CAUTION: Proper safety precautions must be taken when testing the IAC motor. - Set the parking brake and block the drive wheels - Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust components - Provide proper ventilation while operating the engine - Always return the engine idle speed to normal before disconnecting the exerciser tool. - Follow scan tool manufacturer's instructions for testing the IAC motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3069 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig 109 Servicing Idle Air Control Motor NOTE: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. - Never use lubricants on 0-rings or seals, damage may result. - If assembly of component is difficult, use water to aid assembly. - Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battory; 2. Remove electrical connector from idle air control motor. 3. Remove idle air control motor mounting screws (Fig. 109). 4. Remove motor from throttle body. Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 2 Nm (17 in lb) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication Information Bus: Description and Operation Vehicle Communication The body system consists of a combination of modules that communicate over the CCD (Chrysler Collision Detection multiplex system) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has higher priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle on-board diagnostic systems and the scan tool. Problems with the operation of the bus or scan tool must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed: Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either or both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either or both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not Receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Vehicle Communication > Page 3074 Information Bus: Description and Operation CCD Bus Circuit Operation CIRCUIT OPERATION The CCD Bus is used to supply all of the communications between the Body Control Module (BCM), other vehicle controllers and the instrument cluster. The bus wires are a twisted pair. There are two different circuits used for the bus. The positive side of the bus wire is accomplished on the D1 circuit. and the negative is on the D2 circuit. To allow the Body Control Module (BCM) to communicate and control various vehicle functions the BCM uses the CCD bus. This is a twisted pair of wires that connects to the other modules and controllers. Circuits D1 and D2 are used for the communication interface. Circuit D1 is used for the CCD (+), and circuit D2 is used for CCD (-). The CCD BUS and the universal data link connector are used for access to the diagnostic capabilities of the radio. Circuits D1 and D2 are used. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3078 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3079 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3080 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3081 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3087 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3088 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3089 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3090 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3091 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3092 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3093 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3094 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3095 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3096 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3106 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3109 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor ........................................................................................................................................ .......................................................... 4 Nm (35 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3113 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3114 Map Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3115 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3116 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 92 Map Sensor Connector NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3 (Fig. 92). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (4.5 to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3117 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 9 MAP Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake manifold (Fig. 9). 3. Remove sensor from manifold. INSTALLATION - Reverse the above procedure for installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 3122 Oxygen Sensor: Mechanical Specifications Upstream 02S ...................................................................................................................................... ......................................................... 27 Nm (20 ft lb) Downstream 02S ................................................................................................................................. ......................................................... 27 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Oxygen Sensor Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3125 Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector > Page 3128 Downstream Heated Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3129 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3130 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3133 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3134 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground. - The white wires in the sensor connector are the power and ground circuits for the heater. - Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. 3. Resistance should be between 4 and 7 ohms. - If not replace the sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement Fig 122 Oxygen Sensor Grommet Cover WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122). Fig 123 Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123). Fig 124 Oxygen Sensor Removal & Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3137 - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3138 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Fig 121 Upstream Heated Oxygen Sensor The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121). CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM Auto Lamp DTC Diagnostics Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3146 Body Control Module Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Body Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 Body Control Module: Electrical Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 Exterior Lighting (Park Lamps) Information Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 Instrument Cluster Interior Lighting Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 Power Door Locks W/Remote Keyless Entry (RKE) Power Door Locks W/O Remote Keyless Entry (RKE) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Radio (CCD) Without Infinity Sound Radio (CCD) With Infinity Sound Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Vehicle Communications Vehicle Theft Security System (VTSS) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 Windshield Wiper (Front) Windshield Wiper (Rear) Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 Body Control Module (Part 1 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 Body Control Module (Part 2 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Body Control Module (Part 3 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 Body Control Module (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3182 Body Control Module (Part 5 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3183 Body Control Module (Part 6 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3184 Body Control Module (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following approved procedures is very important to the safety of individuals performing diagnostic tests. DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 3187 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Servicing Sub-Assemblies Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced. DRBIII Safety Information WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: FUNCTION/INPUT LIMIT Volts 0 - 500 peak volts AC 0 - 500 volts DC Ohms (resistance)* 0-1.12 megohms Frequency Measured 0 - 10 kHz Frequency Generated 0 - 10 kHz Temperature -58 - 11000 F -50 - 600 C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ The circuit being tested must be protected by a 1OA fuse or circuit breaker. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code Body Control Module: Application and ID Body Code Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager Body Code = NS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code > Page 3190 Body Control Module: Application and ID Glossary of Terms ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The following terms are used interchangeably: - Left Front (LF) Door & Driver (DR) Door - Right Front (RF) Door and Passenger (PASS) Door - "Gage" and "Gauge" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3193 Body Control Module: Description and Operation Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3194 Body Control Module: Description and Operation Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3195 Body Control Module: Description and Operation Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3196 Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3197 - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Compass Mini-Trip Computer (CMTC) The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Auto Headlamps On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless Entry (RKE) actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off the exterior lamps as described above. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Headlamp Time Delay The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body. Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. Identification of System Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3198 The vehicle systems that are part of the "body" system are: - airbag system - chimes - compass/mini-trip - courtesy lamps I panel dimming - headlamp time delay - illuminated entry - radio (CCD) - information center - mechanical instrument cluster (MIC) - power door locks - remote keyless entry (RKE) - vehicle communications - vehicle theft security system (VTSS) - wipers Vehicles equipped with the highline body control module can be identified by the presence of the vehicle theft security system (VTSS). Vehicles with the midline body control module may have a compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or illuminated entry. Vehicles with a base body control module will not have any of these features. Introduction Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover all the necessary requirements to begin a logical diagnostic path for each repair. If there is a trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are used to direct you alphabetically to the specific systems. NOTE: The following terms are used interchangeably: Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door Mechanical Instrument Cluster (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. Power Door Lock System When the body control module (BCM) receives an input for a lock request (door lock switch, RKE, or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power door lock features: Sliding Door Memory Lock When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay as described above, and will turn it on again when all sliding doors are closed. NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3199 RKE (Remote Keyless Entry) Interface The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Radio System There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3200 been activated. System Self-Test NOTE: System self-test can be entered only with the DRB. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Shipping Mode By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle. The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation System Coverage These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth Voyager vehicles equipped with either base, midline, or highline body control modules. Airbag Trouble Code Descriptions Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in the airbag section to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with "AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes An airbag trouble code becomes active and stored as soon as it is detected with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3201 malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire harness and connectors. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal Diagnostic 2 - AECM Internal Diagnostic 1 - AECM Output Driver - AECM Stored Energy - Internal Diagnostic 3 - Incorrect AECM For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - No CCD Communication - Driver Squib Circuit Shorted - Passenger Squib Circuit Open - Driver Squib Term Shorted to Battery - Passenger Squib Circuit Shorted - Driver Squib Term Shorted to Ground - Pass Squib Term Shorted to Battery - Loss of Ignition Run Only - Pass Squib Term Short to Ground - Loss of Ignition Run/Start - Warning Lamp Circuit Open - Output Driver Not Tested - Warning Lamp Circuit Shorted Driver Squib Circuit Open NAME OF CODE Driver Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring open or high resistance in clockspring - Driver side airbag module open - Driver airbag line 1 or line 2 open - Loose or poor connection at connector terminals Driver Squib Circuit Shorted NAME OF CODE Driver Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring short - Driver side airbag module short Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3202 - Driver airbag line 1 shorted to line 2 - Loose, or poor connector not completely connected Driver Squib Term Shorted to Battery NAME OF CODE Driver Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to voltage - Driver airbag line 2 short to voltage - Faulty clockspring - Faulty airbag control module Driver Squib Term Shorted to Ground NAME OF CODE Driver Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to ground potential - Driver airbag line 2 short to ground potential - Faulty clockspring - Faulty airbag control module Loss of Ignition Run Only NAME OF CODE Loss of Ignition Run Only NOTE: This code becomes active as soon as the condition is detected (this is not a stored code). WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Open ignition run circuit - Open fuse - Ignition run circuit short to ground - Loose or poor connection at connector terminals Loss of Ignition Run/Start NAME OF CODE Loss of Ignition Run/Start NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3203 - Open ignition run/start circuit - Open fuse - Ignition run/start circuit short to ground - Loose or poor connection at connector terminals Passenger Squib Circuit Open NAME OF CODE Passenger Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) open - Passenger airbag line 1 or line 2 open - Loose or poor connection at connector terminals Passenger Squib Circuit Shorted NAME OF CODE Passenger Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) short - Passenger airbag line 1 shorted to line 2 - Loose or poor connection at connector terminals Pass Squib Term Shorted to Battery NAME OF CODE Pass Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to voltage - Passenger airbag line 2 short to voltage - Faulty airbag control module Pass Squib Term Shorted to Ground NAME OF CODE Pass Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to ground potential Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3204 - Passenger airbag line 2 short to ground potential - Faulty airbag control module Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NAME OF CODE Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or during a lamp check. SET CONDITION With the voltage on, the airbag warning lamp driver circuit is other than expected. POSSIBLE CAUSES - Faulty warning lamp - Open fused ignition switch output circuit to Information Center - Airbag warning lamp driver circuit short to ground - Airbag warning lamp driver circuit short to voltage - Faulty information center printed circuit board - Loose or poor connection at connector terminal Output Driver Not Tested NAME OF CODE Output Driver Not Tested WHEN MONITORED At ignition on. SET CONDITION This code may set whenever another code is set due to any short to battery or short to ground failure of the squib circuits. If all other squib codes have been repaired and this code appears active by itself, the problem will be an internal failure of the airbag control module. POSSIBLE CAUSES - Short circuit to ground or to battery in either driver or passenger airbag lines - Defective airbag control module Trouble Code Testing Notes Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes. It is not necessary to perform all of the tests to diagnose an individual code. The body control module will set a diagnostic trouble code if a monitored input is determined to be malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the trouble code condition is removed, the body control module will back out the diagnostic trouble code if the trouble code condition remains cleared for twenty ignition cycles. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This will direct you to the specific test(s) that must be performed. ASB Message Not Received NAME OF CODE ASB Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from CAB every second. If this message is not received by the BCM for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from CAB to BCM Airbag Message Not Received Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3205 NAME OF CODE Airbag Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from ACM every second. It this message is not received by the BCM for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from ACM to BCM Battery Power to Module Disconnected NAME OF CODE Battery Power to Module Disconnected WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION Battery power to the BCM is disconnected while the ignition is on. THEORY OF OPERATION The body control module checks battery input and determines if the battery is connected. POSSIBLE CAUSES - In shipping mode - IOD fuse missing - Open wire - Blown IOD fuse EATX PRNDL Message Test Failed NAME OF CODE EATX PRNDL Message Test Failed WHEN MONITORED When engine is running. SET CONDITION The engine is running above 450 rpm and the body control module has not received a transmission PRNDL message. THEORY OF OPERATION The body control module will monitor the CCD bus and look for the transmission PRNDL message whenever the engine rpm is above 450. POSSIBLE CAUSES - Body Control module - Transmission control module - CCD bus failure - Loss of power to transmission control module EEPROM Checksum Failure NAME OF CODE EEPROM Checksum Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The sum of EEPROM constants does not equal the correct value. THEORY OF OPERATION By using a checksum, the BCM monitors the value of each programmable constant. The code is set if any value is incorrect. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3206 - Body Control module Front Wiper Park Switch CKT Open NAME OF CODE Front Wiper Park Switch Ckt Open WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Open wire - Wiper motor - Body Control module Front Wiper Park Switch CKT-Shorted NAME OF CODE Front Wiper Park Switch Ckt-Shorted WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Shorted wire - Wiper motor - Body Control module Fuel Level Sending Circuit Error NAME OF CODE Fuel Level Sending Circuit Error WHEN MONITORED With the ignition key on and battery voltage above 10 volts. SET CONDITION When the BCM senses an open or short on the fuel level sensor signal circuit. THEORY OF OPERATION The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be set. POSSIBLE CAUSES - Open wire - Shorted wire - Fuel level sending unit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3207 - Body control module Internal Module Test Failed NAME OF CODE Internal Module Test Failed WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The body control module performs an internal check and determines the body control module is not functioning properly. THEORY OF OPERATION The body control module performs internal diagnostics on demand and determines if the body control module microprocessor is functioning properly. POSSIBLE CAUSES - Body control module Left Door Key CYL Arm SW Failure NAME OF CODE Left Door key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Key CYL Disarm SW Failure NAME OF CODE Left Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Lock Switch Failure NAME OF CODE Left Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3208 SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Left Door Unlock Switch Failure NAME OF CODE Left Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Liftgate Key CYL Arm SW Failure NAME OF CODE Liftgate Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Key CYL Disarm SW Failure NAME OF CODE Liftgate Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3209 level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Door Mux CKT Short to GND NAME OF CODE Liftgate Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (Liftgate Switch MUX) - Body control module LT Front Door Mux Circuit Short to GND NAME OF CODE LT Front Door MUX Circuit Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (LF Door Switch MUX) - Body control module No CCD Message From PCM NAME OF CODE No CCD Message From PCM WHEN MONITORED When the ignition is in the run or start position and battery voltage is above 10 volts. SET CONDITION The BCM looks for engine messages over the CCD bus and does not receive a message within a 2-second period. THEORY OF OPERATION The body control module will monitor the engine messages after the ignition has been turned on. POSSIBLE CAUSES - Body control module - Powertrain control module - CCD Bus failure Rear Wiper Mux Circuit Error NAME OF CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3210 Rear Wiper MUX Circuit Error WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts. SET CONDITION When the rear wiper MUX circuit senses a voltage above 5.0 volts. THEORY OF OPERATION The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level. The voltage level will determine the wiper function to be performed. That level will be below 5.0 volts. POSSIBLE CAUSES - Circuit shorted to battery - Open CCM ground circuit Right Door Key CYL Arm SW Failure NAME OF CODE Right Door Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Key CYL Disarm SW Failure NAME OF CODE Right Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Lock Switch Failure NAME OF CODE Right Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3211 THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module Right Door Unlock Switch Failure NAME OF CODE Right Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module RT Front Door Mux CKT Short to GND NAME OF CODE RT Front Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below .4 volts on the RF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (RF Door Switch MUX) - Body control module Horn Switch Failure NAME OF CODE Horn Switch Failure WHEN MONITORED Continuously with battery connected and IOD fuse installed. SET CONDITION The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to cool down. POSSIBLE CAUSES - Shorted horn relay control circuit - Defective horn switch - Defective BCM Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3212 CCD Radio NAME OF CODE CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume Down Switch (Stuck) Preset Switch (Stuck) WHEN MONITORED Anytime ignition is on and voltage is above 10.0 volts. SET CONDITION When a switch is held active for longer than 20 seconds. THEORY OF OPERATION The BCM monitors the control switches for an active condition and performs the required radio function. When a switch is active for longer than 10 seconds, that switch function will be disabled until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be set. POSSIBLE CAUSES - Defective remote control switch - Shorted radio control MUX circuit Vehicle Communication The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 3213 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Wiper System FRONT The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned off, the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. REAR The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics SELF DIAGNOSTIC TEST To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about five seconds) then release the buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarily appear. INSTRUMENT CLUSTER DTC CHART DTC ..................................................................................................................................................... .................................................... Description 110 ............................................................................... .......................................................................................................... Memory Fault in cluster 111 ..... .............................................................................................................................................................. ................... Calibration fault in cluster 905 ......................................................................................... ................................................................................ No CCD bus messages from TCM 921 .............. .............................................................................................................................................................. ......... Odometer fault from BCM 940 ................................................................................................... ...................................................................... No CCD bus messages from PCM 999 ........................ .............................................................................................................................................................. .................... End of Codes NOTE: For DTC testing see Condition Diagnostic Charts below. CONDITIONS Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis - Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis - Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis - Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis - Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis - Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis - Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21) CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). CLUSTER CALIBRATION TABLE Speedometer ....................................................................................................................................... ................................................. Calibration Point 1 ........................................................................................................................................................... ............................................... 0 mph (0 Km/h) 2 ................................................................................. ..................................................................................................................... 20 mph (40 Km/h) 3 ....... .............................................................................................................................................................. ................................. 55 mph (80 Km/h) 4 ........................................................................................... .......................................................................................................... 75 mph(120 Km/h) Tachometer ......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ............................................................... 0 rpm 2 ................................................................................ .................................................................................................................................... 1000 rpm 3 ..... .............................................................................................................................................................. ................................................. 3000 rpm 4 ........................................................................................ ............................................................................................................................ 6000 rpm Fuel Gauge .......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ......................................................... Empty(E) 2 ................................................................................. ................................................................................................................................... 1/8 Filled 3 ....... .............................................................................................................................................................. ............................................... 1/4 Filled 4 ........................................................................................... ............................................................................................................................ Full (F) Temperature Gauge ............................................................................................................................ ............................................... Calibration Point 1 ........................................................................................................................................................... .......................................................... Cold (C) 2 ................................................................................. .............................................................................................................................. Low Normal 3 ....... .............................................................................................................................................................. ......................................... High Normal 4 ............................................................................................ ........................................................................................................................... Hot (H) DIM TEST When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3216 no change, a problem exists in the cluster. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 3217 Body Control Module: Scan Tool Testing and Procedures Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions. DRBIII Error Messages Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the scantool manufacturer for information and assistance. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3218 Body Control Module: Service and Repair Body Control Module Location REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4. Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION 1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5. Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker reinforcement. 8. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3219 Body Control Module: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge (0-300 psi) - Test Light - Voltmeter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Fig 1 Powertrain Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3225 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3226 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3227 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3228 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3229 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3230 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3231 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3232 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3233 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3234 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3235 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3236 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3237 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3238 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3239 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3240 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3241 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3242 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3243 Powertrain Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3244 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3245 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3246 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3247 Powertrain Control Module: Service Precautions Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3248 Powertrain Control Module: Description and Operation Fig 1 Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input signals from various switches and sensors that are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to as PCM Outputs. PCM Inputs: Air Conditioning Head Pressure - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Engine Coolant Temperature Sensor - Heated Oxygen Sensors (Upstream and Downstream) - Knock Sensor - Manifold Absolute Pressure (MAP) Sensor - SCI Receive - Speed Control System Controls - Throttle Position Sensor - Transaxle Park/Neutral Position Switch (automatic transaxle) - Transmission Control Module - Vehicle Speed Sensor PCM Outputs: Air Conditioning Clutch Relay - Automatic Shutdown (ASD) Relay - Data Link Connector - Electric EGR Transducer - Fuel Injectors - Fuel Pump Relay - Generator Field - Idle Air Control Motor - Ignition Coil - Leak Detection Pump - Malfunction Indicator (Check Engine) Lamp - Proportional Purge Solenoid - Radiator Fan Control Module - Speed Control Solenoids - Tachometer Output - Torque Converter Clutch Solenoid (3 speed transmission) - Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3249 Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage - Engine coolant temperature - Exhaust gas content (oxygen sensors) - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position The PCM adjusts ignition timing based on the following inputs: Barometric pressure - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) The PCM also adjusts engine idle speed through the idle air control motor based on the following inputs: Air conditioning select switch head pressure - Brake switch - Engine coolant temperature - Engine speed (crankshaft position sensor) - Manifold absolute pressure - Throttle position - Transaxle gear selection (park/neutral switch) - Vehicle distance (speed) Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump relays are located in the Power Distribution Center (PDC). The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump. PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute pressure sensor, throttle position sensor and engine coolant temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3250 Powertrain Control Module: Service and Repair Fig 29 Power Distribution Center Retaining Screws REMOVAL 1. Disconnect both cables from battery, negative cable first. NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection 2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29). Fig 30 Battery Heat Shield 3. Remove heat shield from battery (Fig 30). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3251 Fig 31 Battery Clamp 4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle. Fig 32 PDC Rear Bracket 6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3252 Fig 33 PCM 40 Way Connectors 8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33). Remove both way connectors. Fig 34 PCM Removal/Installation 9. Remove 3 screws holding PCM to fender (Fig. 34). 10. Remove PCM from vehicle. INSTALLATION 1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting screws. 3. Install PDC bracket. 4. Install battery. NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be set. IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 3253 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3259 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3260 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3261 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3262 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3263 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3269 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3270 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3271 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3272 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3273 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3274 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3275 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3276 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3278 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3281 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3290 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3291 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3314 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3315 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3316 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3317 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3318 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Coolant Sensor .................................................................................................................................... .......................................................... 7 Nm (62 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3322 Engine Coolant Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3323 Engine Coolant Temperature Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3324 Coolant Temperature Sensor/Switch (For Computer): Description and Operation PURPOSE The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle speed, and ignition spark advance. OPERATION The sensor element extends into the coolant passage, where it maintains constant contact with the engine coolant. The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature increases, sensor resistance decreases.) The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant temperature varies, the sensors resistance changes, resulting in a different input voltage to the PCM. The PCM contains different spark advance schedules for cold and warm engine operation. The schedules reduce engine emission and improve driveability. When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle speeds until normal operating temperatures are reached. The ECT sensor input is also used for cooling fan control. The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below. As sensor resistance changes, the voltage drop across the sensor changes. The PCM translates the voltage drop across the sensor into engine coolant temperature. THEORY As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor (cold operation), or a 909 ohm resistor (warm operation). The resistance circuits are inside the PCM. For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the 10,000 ohm resistor. When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the 909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3325 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 95 Engine Coolant Temperature Sensor 1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95). Fig 96 Engine Coolant Temperature Sensor Connector 2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The ohmmeter should read as follows: - Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000 ohms. - Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms. 3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor harness connector. Also check for continuity between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3326 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 129 Engine Coolant Temperature Sensor WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially drained before removing the coolant temperature sensor. Refer to Cooling System. NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil. REMOVAL 1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine. INSTALLATION 1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill cooling system. Refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3330 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3353 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3354 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3355 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3356 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Tank Sending Unit Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3363 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3364 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3365 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3366 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications MAP Sensor ........................................................................................................................................ .......................................................... 4 Nm (35 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3370 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3371 Map Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3372 Manifold Pressure/Vacuum Sensor: Description and Operation PURPOSE At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric), pressure, for reference, to calculate air/fuel mixture. During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark advance and air/fuel mixture. OPERATION PCM supplies 5 volt sensor reference voltage. Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into voltage. THEORY Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute pressure increases, (low vacuum), sensor resistance decreases and vice versa). OUTPUT VOLTAGES Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or deceleration. - Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or slight acceleration condition. - Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard acceleration or a mechanical failure. - Any reading of 0 volts or over 5 volts indicates a problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3373 Manifold Pressure/Vacuum Sensor: Testing and Inspection Fig 92 Map Sensor Connector NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following: CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the test meter probes. 1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3 (Fig. 92). With the ignition switch ON and the engine not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a hot, neutral idle speed condition. If OK, go to next step. - If not OK, go to step 3. 2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness condition. - Repair as required. 3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43. - If OK, go to next step. - If not OK, repair as required. 4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON. The voltage should be approximately 5 volts (4.5 to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor. - If not OK, repair or replace the wire harness as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 3374 Manifold Pressure/Vacuum Sensor: Service and Repair Fig 9 MAP Sensor REMOVAL 1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake manifold (Fig. 9). 3. Remove sensor from manifold. INSTALLATION - Reverse the above procedure for installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications Oxygen Sensor: Electrical Specifications Air/Fuel Oxygen Exhaust Ratio Sensor Voltage Gas Content 12.0:1 1.0 Volts [1] 5.0% CO [2] 13.0:1 0.85 Volts 3.8% CO [2] 14.0:1 0.65 Volts 1.3% CO [2] 14.7:1 0.45 Volts [5] 0.1% CO [2] 15.0:1 0.35 Volts 2.0% O2 [3] 16.0:1 0.25 Volts 3.0% O2 [3] 17.0:1 0.10 Volts [4] 4.0% O2 [3] Remarks [1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts indicate a lean condition, and output voltages over 0.45 volts indicate a rich condition. NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings. Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all hydrocarbons). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications > Page 3379 Oxygen Sensor: Mechanical Specifications Upstream 02S ...................................................................................................................................... ......................................................... 27 Nm (20 ft lb) Downstream 02S ................................................................................................................................. ......................................................... 27 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations Oxygen Sensor Bank Locations The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Oxygen Sensor Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3382 Oxygen Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor Connector > Page 3385 Downstream Heated Oxygen Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3386 Oxygen Sensor: Application and ID The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1. The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2. A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3. The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1. The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2. - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3387 Oxygen Sensor: Description and Operation O2 Sensor Cutaway View (Typical) SENSOR PURPOSE Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel mixture, during closed loop operation. SENSOR OPERATION The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen content at that point in the exhaust. - Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors. Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the system is responding to its output signals. - Changes in the sensor signal occur because the air/fuel ratio is constantly changing. - When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt. - When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt. Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width according to the current driving condition. Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and other sensor's signals, and adjusts injector pulse widths according to preprogrammed specifications in the PCM. HEATER PURPOSE Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner). Allows CLOSED LOOP operation during extended idle, (because heater maintains correct operating temperature). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test Oxygen Sensor And Connector NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test. NOTE: When performing this test it is important that no part of your body contact the vehicle body, as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor wire. PRECONDITIONING AND SET UP 1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T), (to ensure vehicle and oxygen sensor are at operating temperature and vehicle is in closed loop). 2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK (A/T), or NEUTRAL (M/T). 4. Let idle. LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery negative, hold for 10 to 20 seconds. - The CO and HC readings should increase, as the PCM opens the injectors for longer periods (longer pulse width), to enrich the mixture. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE) 1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery positive, hold for 10 to 20 seconds. - The O2 readings should begin to increase, and the CO reading should decrease. 2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or engine control system will be necessary. SEE DIAGNOSIS BY SYMPTOM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3390 Oxygen Sensor: Testing and Inspection Sensor Functional Test Oxygen Sensor And Connector CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing components on computerized vehicles. 1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL (M/T). CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms). 2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to read DC VOLTS. Disconnect the oxygen sensor ( O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal wire. 3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is defective. 6. Connect sensor and clear codes. Remarks: [1] Minimum 10 Meg (10,000,000) ohm input impedance. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3391 Oxygen Sensor: Testing and Inspection Sensor Heating Element Test 1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2. Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground. - The white wires in the sensor connector are the power and ground circuits for the heater. - Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor connector. 3. Resistance should be between 4 and 7 ohms. - If not replace the sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement Fig 122 Oxygen Sensor Grommet Cover WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122). Fig 123 Oxygen Sensor Connector Locking Tab 3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123). Fig 124 Oxygen Sensor Removal & Installation 4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3394 - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3395 Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement Fig 121 Upstream Heated Oxygen Sensor The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121). CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector. WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when servicing the oxygen sensor. REMOVAL 1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION 1. Reverse removal procedure to install a new sensor. - New sensors are packaged with compound on the threads and no additional compound is required. - The sensor must be tightened to 27 Nm (20 ft lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3400 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3401 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3402 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3403 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3404 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3405 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3414 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3415 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3416 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3422 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3423 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3428 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3429 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3430 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3436 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3437 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3440 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3441 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3442 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3443 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3444 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3445 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM) transmits the vehicle speed signal to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3471 Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor. CIRCUIT OPERATION The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that information to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3472 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical OPERATION The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The speed and distance signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired MAP value. - Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine speed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 3473 Vehicle Speed Sensor: Testing and Inspection For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3478 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3479 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3480 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3481 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3482 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3483 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Torque Reduction Signal > Component Information > Description and Operation Torque Reduction Signal: Description and Operation OPERATION The torque reduction data link line is connected between the Transmission Control Module (TCM) and the Powertrain Control Module (PCM). It is used as a communication link for the TCM to instruct the PCM to back down the engine torque output before the vehicle shifts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3495 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3496 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3497 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3503 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3504 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3509 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3510 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3511 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3517 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3518 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3521 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 3522 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3523 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3524 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3525 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3526 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations Fig. 26 Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The output speed sensor is located on the side of the transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3532 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation Vehicle Speed Sensor: Description and Operation Circuit Operation CIRCUIT OPERATION If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM) transmits the vehicle speed signal to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3552 Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor. CIRCUIT OPERATION The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that information to the Powertrain Control Module (PCM). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit Operation > Page 3553 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical OPERATION The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM. The speed and distance signals, along with a closed throttle signal from the TPS, determine if a closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired MAP value. - Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine speed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page 3554 Vehicle Speed Sensor: Testing and Inspection For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also refer to the DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component Information > Description and Operation Voltage Signal: Description and Operation PURPOSE Supplies Powertrain Control Module (PCM), with current charging system voltage. OPERATION If the PCM senses low battery voltage: - PCM increases injector pulse width to compensate for low voltage. - PCM increases generator field voltage. If the PCM senses high battery voltage: - PCM decreases injector pulse width to compensate for high voltage. - PCM decreases generator field voltage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter Technical Service Bulletin # J25 Date: 091030 Recall - Replace Mopar(R) Value Line Catalytic Converter October 2009 Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters Models 1997 - 1999 (AN) Dodge Dakota 1998 - 1999 (BE) Dodge Ram Truck 1995 - 1999 (BR) Dodge Ram Truck 1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon 1996 - 1997 (LH) Chrysler LHS and Concorde 1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country 1998 (PL) Plymouth Neon 2003 (PT) Chrysler PT Cruiser 1998 - 1999 (TJ) Jeep(R) Wrangler 2001 (WJ) Jeep(R) Grand Cherokee 1994 (XJ) Jeep(R) Cherokee 1994 - 1995 (YJ) Jeep(R) Wrangler 1993 - 1998 (ZJ) Jeep(R) Grand Cherokee NOTE: This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter installed. IMPORTANT: Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar Value Line catalytic converter was installed on about 47 of the above vehicles. These catalytic converters may fail an emissions inspection test. Repair The catalytic converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3567 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3568 Use the labor operation number and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE TORCH FLAME NEAR THE FUEL LINES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3569 1. Raise and support the vehicle on an appropriate hoist. 2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection. 4. Remove the exhaust clamp from the catalytic converter muffler connection. 5. Disconnect the oxygen sensor wiring. 6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal becomes cherry red. 7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from the exhaust pipe and the muffler. 8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter. 9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection. 10. Install the catalytic converter onto the exhaust pipe. 11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the alignment slot. 12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 45 ft. lbs. (61 N.m). 13. Connect the oxygen sensor wiring. 14. Lower the vehicle from the hoist. 15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. 16. Continue with Section B. Install the Authorized Modifications Label. B. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the Authorized Modifications Label. Then attach the label near the VECI label. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3570 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter Technical Service Bulletin # J25 Date: 091030 Recall - Replace Mopar(R) Value Line Catalytic Converter October 2009 Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters Models 1997 - 1999 (AN) Dodge Dakota 1998 - 1999 (BE) Dodge Ram Truck 1995 - 1999 (BR) Dodge Ram Truck 1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon 1996 - 1997 (LH) Chrysler LHS and Concorde 1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country 1998 (PL) Plymouth Neon 2003 (PT) Chrysler PT Cruiser 1998 - 1999 (TJ) Jeep(R) Wrangler 2001 (WJ) Jeep(R) Grand Cherokee 1994 (XJ) Jeep(R) Cherokee 1994 - 1995 (YJ) Jeep(R) Wrangler 1993 - 1998 (ZJ) Jeep(R) Grand Cherokee NOTE: This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter installed. IMPORTANT: Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar Value Line catalytic converter was installed on about 47 of the above vehicles. These catalytic converters may fail an emissions inspection test. Repair The catalytic converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3576 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3577 Use the labor operation number and time allowances shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE TORCH FLAME NEAR THE FUEL LINES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3578 1. Raise and support the vehicle on an appropriate hoist. 2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration. 3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection. 4. Remove the exhaust clamp from the catalytic converter muffler connection. 5. Disconnect the oxygen sensor wiring. 6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal becomes cherry red. 7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from the exhaust pipe and the muffler. 8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter. 9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection. 10. Install the catalytic converter onto the exhaust pipe. 11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the alignment slot. 12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 45 ft. lbs. (61 N.m). 13. Connect the oxygen sensor wiring. 14. Lower the vehicle from the hoist. 15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels. 16. Continue with Section B. Install the Authorized Modifications Label. B. Install the Authorized Modifications Label: Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the Authorized Modifications Label. Then attach the label near the VECI label. C. Complete Proof of Correction Form for California Residents: This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R) Value Line Catalytic Converter > Page 3579 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3580 Catalytic Converter: Service Precautions NOTE: There is no regularly scheduled maintenance on the catalytic converter. If damaged, the converter must be replaced. CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts. There are internal converter differences required in some parts of the country. REACTION The combustion reaction caused by the catalyst releases additional heat in the exhaust system. Causing temperature increases in the area of the reactor under severe operating conditions. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by unburned fuel passing through the converter. CATALYSTS The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan temperatures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3581 Catalytic Converter: Description and Operation Three Way Catalyst (TWC) PURPOSE Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and Oxides of Nitrogen (NOx)), by up to 90%. OPERATION Oxidation Reaction As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation (burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor (H2O) and Carbon Dioxide (CO2). This process no effect on NOx emissions. Reduction Reaction The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal of oxygen), reaction. OPERATING ENVIRONMENT A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only be achieved in a properly functioning feedback system with oxygen sensor. The ideal converter operating temperature, for maximum emission reduction and long service life is, 400°C - 800°C (750°F - 1500°F). Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede 1400°C (2500°F), which can melt substrate material. CONSTRUCTION Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately 2 grams of platinum and rhodium). CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material, reducing or eliminating catalyst activity. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Catalytic Converter: Initial Inspection and Diagnostic Overview VISUAL INSPECTION Inspect Catalytic converter for external cracks. Repair or replace as necessary. BACK PRESSURE CHECK If excessive exhaust back pressure is suspected, eliminate the exhaust system as a cause. If exhaust back pressure remains excessive with all mufflers disconnected, the catalytic converter may be plugged. LOOSE CORE CHECK If the exhaust system rattles during engine operation, check the catalytic converter for a loose core. With the vehicle raised (for access), tap the catalytic converter with a rubber mallet. If the converter rattles, the core is loose and the converter must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3584 Catalytic Converter: Component Tests and General Diagnostics Catalytic Converter Functional Test NOTE: If all other emission systems are functioning correctly, but vehicle still has excessive tailpipe emissions, the catalytic converter core may by contaminated. To check converter effectiveness, perform the following test: FUNCTIONAL CHECK 1. Warm the engine to normal operating temperature. 2. Run the engine at 2500 RPM for 30 seconds. 3. Using a pyrometer, measure the exhaust pipe temperature before and after the catalytic converter. 4. Exhaust pipe temperature should be at least 100° F hotter at the converter outlet than at the inlet. 5. If catalytic converter has little or no effect on exhaust temperature, the core may be contaminated. NOTE: If exhaust temperature exceeds 450° F, the engine may be running too lean. Repair the lean running condition and recheck exhaust temperature before condemning the catalytic converter. At Oxygen Sensor Opening Pressure Testing The Exhaust System at The Oxygen Sensor NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel system problems, then perform a visual inspection of the exhaust system. If the condition cannot be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT OXYGEN SENSOR OPENING 1. Carefully remove O2 sensor using proper tool. 2. Install Exhaust Backpressure Tester in place of 02 sensor. 3. With the engine at normal operating temperature and running at 2500 rpm, observe the exhaust system backpressure reading on gauge. 4. If backpressure exceeds 1-1/4 psi (8.62 kPa), a restricted exhaust system is indicated. 5. Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffler failure. 6. If there are no obvious reasons for the excessive backpressure, a restricted catalytic converter should be suspected, and replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3585 NOTE: Prior to installing O2 sensor: - Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap. - Coat sensor threads with a nickel based anti-seize compound (Loctite 771-64 or equivalent). Do not use graphite or other anti-seize compounds. Using Manifold Vacuum Port NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel system problems, then perform a visual inspection of the exhaust system. If the condition cannot be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT MANIFOLD VACUUM PORT 1. With engine at normal operating temperature, connect a vacuum gauge to any convenient manifold vacuum source. 2. Run engine at 1,000 rpm and record vacuum reading. 3. Increase rpm slowly to 2,500 rpm, and note vacuum reading at a steady 2.500 rpm. 4. If vacuum at 2,500 rpm decreases more than 3" Hg, from reading at 1000 rpm, the exhaust system should be inspected for restrictions. 5. Disconnect exhaust pipe from engine and repeat Step 3 & 4. If vacuum still drops more than 3" Hg, with exhaust disconnected, check for exhaust manifold restriction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Fig 49 Proportional Purge Solenoid Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3591 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3592 Canister Purge Solenoid: Description and Operation Fig 49 Proportional Purge Solenoid PURPOSE All vehicles use a Proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. OPERATION During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3593 Canister Purge Solenoid: Service and Repair Fig 49 Proportional Purge Solenoid REMOVAL 1. Remove vacuum hose and electrical connector from solenoid. 2. Pull solenoid up to remove it from mounting bracket. INSTALLATION Reverse above procedure for installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Fig 1 Evaporative Canister All vehicles use a sealed, maintenance free, evaporative (charcoal) canister. The canister is attached to the frame under the driver's seat (Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3597 Evaporative Emission Control Canister: Description and Operation Fig 1 Evaporative Canister All vehicles use a sealed, maintenance free, evaporative (charcoal) canister. The canister is attached to the frame under the driver's seat (Fig. 1). Fuel tank vapor vents into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The canister proportional purge solenoid allows the canister to be purged at predetermined intervals and engine conditions. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak Detection Pump Misdiagnosis Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump Misdiagnosis NUMBER: 18-01-00 GROUP: Vehicle Performance DATE: Feb. 4, 2000 SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR P0456 MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck 1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA) Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH) Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ) GrandCherokee DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494 (LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply vacuum lines examined for pinches or kinks prior to any LDP component replacement. The supply vacuum lines should be checked from the engine compartment all the way to the fuel tank, including the LDP and purge system. NOTE: VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3602 Leak Detection Pump: Locations Evaporative Leak Detection Pump The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under the steering gear. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3603 Leak Detector Pump Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3604 Leak Detection Pump: Description and Operation Leak Detection Pump (LDP) Operation And Diagnosis This bulletin describes the theory of operation for the leak detection system. In addition, information is provided for each of the Diagnostic Trouble Codes (DTC's) as follows: P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT INTRODUCTION The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require on-board testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3605 EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. Leak Detection Pump (LDP) Components The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3606 LDP AT REST (NOT POWERED) When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3607 DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3608 DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3609 Leak Detection Pump: Testing and Inspection ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST NOTE: The following values are approximate and vehicle specific. Use the values seen in pre test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail 1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40° F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2. Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage between 10 and 15 volts. NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the EVAP leak detection test will not run. 4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and 85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute pressure, not vacuum). 6. No engine stall during test. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following: - Purge Solenoid Electrical Fault - All Engine Controller Self Test Faults - All Cam And/or Crank Sensor Fault - All Map Sensor Faults - Ambient/battery Temperature Sensor Electrical Faults - All Coolant Sensor Faults - All TPS Faults - LDP Pressure Switch Fault - EGR Solenoid Fault - All Injector Faults - Baro Our Of Range - Vehicle Speed Faults - LDP Solenoid Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3610 Figure 6 EVAP leak detection test sequence When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and a P1494 fault could be set because the PCM is expecting the reed switch to be closed. After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP Leak Detection Test is canceled. NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486, P0442, P0455 and P0441. These temperature calibrations may be different between models. FIGURE 6 SECTION 2 If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in memory, and waits until the next time the Enabling Conditions are met to run the test again. If this is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during the next enabling cycle, the temporary fault will be cleared. However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The PCM stores information in memory on EVAP system purging from previous engine run or drive cycles. If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak Detection Test without setting the temporary fault. If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3611 illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be cleared. FIGURE 6 SECTION 3 If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP system between the LDP and the fuel tank. This is done by monitoring the time required for the LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present, the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run again. If blockage is again detected, P1486 is stored, and the MIL is illuminated. FIGURE 6 SECTION 4 After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First, the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak checking. The LDP reed switch does not close and open during rapid pumping because the diaphragm does not travel through its full range during this part of the test. FIGURE 6 SECTION 5 Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed switch to close (diaphragm to drop) after the LDP solenoid is turned off. If the switch does not close, or closes after a long delay, it means that the system does not have any significant leakage and the EVAP Leak Detection Test is complete. However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by several LDP test cycles may repeat several times before the PCM judges that a leak is present. When leaks are present, the LDP test cycle time will be inversely proportional to the size of the leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present. If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The important point to remember is if a leak is again detected on the next EVAP Leak Detection Test, the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is detected during the next test, the temporary fault will be cleared. DIAGNOSTIC TIPS During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure 6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid activity will stop. As each section of the test begins, it indicates that the previous section passed successfully. By watching to see which tests complete, you can see if any conditions are present that the PCM considers abnormal. For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the test. However, the PCM will assume that the system is already pressurized and skip the rapid pump cycles. Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections may mask a leak condition. Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking. In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP system test. If the purge solenoid cannot properly vent the system the LDP cannot properly complete the test for P1486 and this fault can set due to pressure being in the EVAP system during the test sequence. Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak because of excess vapor generation. Additionally, any source for additional vapor generation can hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle into a warm shop for testing or high ambient temperatures. Fully plugged and partially plugged underhood vacuum lines have been known to set MIL conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for pinches or blockage before condemning components. TEST EQUIPMENT The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually detecting leaks in the evaporative system and will take Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3612 the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful when components have to be removed to determine the exact leak location. For detailed test instructions, follow the operators manual packaged with the EELD. IMPORTANT Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3613 Leak Detection Pump: Service and Repair Fig 9 Leak Detection Pump NOTE: The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under the steering gear (Fig. 9). REMOVAL 1. Raise and support vehicle on a hoist. Fig 10 Leak Detection Pump Connector Lock 2. Push locking tab on connector to unlock (Fig. 10). 3. Push down on connector latch and pull connector from pump. 4. Remove hoses. 5. Remove bolts holding LDP and bracket to cradle. 6. Remove bracket from LDP. INSTALLATION 1. Install LDP to bracket. 2. Install LDP and bracket to cradle. Torque bolts to 9.5-14 Nm (85-125 in lb). - Before installing hoses to LDP, make sure they are not cracked or split. - If a hose leaks, it will cause the Check Engine Lamp to illuminate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3614 3. Install hoses to LDP. 4. Plug electrical connector into LDP. 5. Push connector locking tab into place. 6. Using DRB scan tool, verify proper operation of LDP. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations EGR Backpressure Transducer: Locations EGR Solenoid And Valve Electric EGR Transducer (EET) EGR System Mounted near the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3619 EGR Backpressure Transducer: Description and Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR valve control nipple, (depending on engine load conditions). OPERATION Transducer is supplied ported vacuum through the solenoid. Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no vacuum is applied to the EGR valve. - When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and maximum vacuum is applied to the EGR valve. - When exhaust backpressure is present, but not great enough to close the vacuum bleed valve completely, the vacuum applied to the EGR valve varies with the backpressure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3620 EGR Backpressure Transducer: Testing and Inspection TESTING ELECTRICAL SOLENOID PORTION OF VALVE This is not to be used as a complete test of the EGR system. Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly Fig 4 EGR System TESTING VACUUM TRANSDUCER PORTION OF VALVE NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve has ruptured or is leaking. The second part of the test will determine if engine vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used as a complete test of the EGR system. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to operating temperature. - Hold engine speed at approximately 1,500 rpm. 9. Check for steady engine vacuum (full-manifold) at this hose. 10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4) on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector (Fig. 4) at the valve control. - This will simulate an open circuit (no ground from the PCM) at the valve. 15. Start the engine and bring to operating temperature. 16. Hold the engine speed to approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. - It must be high enough to hold the bleed valve in the transducer portion of the valve closed. - Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3621 vacuum gauge. - Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. 17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. - This low reading is normal. - At idle speed, the gauge reading will be erratic. - This is also normal. 18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Locations > Page 3622 EGR Backpressure Transducer: Service and Repair EGR Mounting REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for signs of leakage or cracks. INSTALLATION 1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and electrical connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations EGR Control Solenoid: Component Locations EGR Solenoid And Valve Electric EGR Transducer (EET) EGR System Mounted near the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 3627 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3628 EGR Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3629 EGR Control Solenoid: Description and Operation EGR Mounting Electric EGR Transducer (EET) NOTE: The Electronic EGR Transducer (EET) assembly is a vacuum control solenoid and a backpressure transducer, in one package. PURPOSE The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the EET. OPERATION Ported vacuum from the throttle body, is supplied to the solenoid valve. The PCM controls the flow of vacuum between the throttle body and the back pressure transducer, (through the solenoid ground circuit). - When the solenoid is energized (grounded), no vacuum is supplied to the transducer. - When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer. The solenoid will always be energized (no EGR), under following conditions: - Engine warm-up, (engine coolant temperature below 40 ~F) - Engine at idle - Wide Open Throttle (WOT) operation - Rapid acceleration/deceleration Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3630 - During EGR system diagnostic check NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at all times, (adversely affecting engine idle and performance). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3631 EGR Control Solenoid: Testing and Inspection TESTING ELECTRICAL SOLENOID PORTION OF VALVE This is not to be used as a complete test of the EGR system. Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly Fig 4 EGR System TESTING VACUUM TRANSDUCER PORTION OF VALVE NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve has ruptured or is leaking. The second part of the test will determine if engine vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used as a complete test of the EGR system. 1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2. Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to operating temperature. - Hold engine speed at approximately 1,500 rpm. 9. Check for steady engine vacuum (full-manifold) at this hose. 10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4) on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical connector (Fig. 4) at the valve control. - This will simulate an open circuit (no ground from the PCM) at the valve. 15. Start the engine and bring to operating temperature. 16. Hold the engine speed to approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting. - To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present at valve. - It must be high enough to hold the bleed valve in the transducer portion of the valve closed. - Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3632 vacuum gauge. - Heavy gloves should be worn. CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. 17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum outlet fitting. - Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low. - This low reading is normal. - At idle speed, the gauge reading will be erratic. - This is also normal. 18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair Fig 6 EGR Tube REMOVAL 1. Remove EGR tube attaching bolts from intake and exhaust manifolds (Fig. 6). 2. Clean intake and exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or cracked surfaces on either manifolds or tube. Repair or replace as necessary. INSTALLATION 1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2. Tighten mounting bolts to 22 Nm (200 in lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Tube to Intake Manifold Screws ....................................................................................................................................................... 22 Nm (200 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3639 EGR Valve: Locations EGR Solenoid And Valve Valve and transducer, mounted near throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3640 EGR Valve: Testing and Inspection Fig 4 EGR System EGR VALVE LEAKAGE TEST This is not to be used as a complete test of the EGR system. If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve (Fig. 4) at the base of the EGR valve may be leaking in the closed position. 1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting (Fig. 4) at the top (vacuum motor) side of the EGR valve. a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c. Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve has ruptured. e. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one assembly. f. Proceed to the next step. 3. A small metal fitting (back-pressure fitting) is located at the base of the EGR valve (Fig. 4). - A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control. - Disconnect this rubber hose at the EGR valve fitting. 4. Remove the air cleaner housing from the throttle body 5. Using compressed air, and an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back-pressure fitting on the EGR valve. 6. By hand, open the throttle to the wide open position. - Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the back-pressure fitting. 7. If air CAN BE HEARD emitting from the intake manifold, the poppet valve (Fig. 4) is leaking at the bottom of the EGR valve. - Replace the EGR valve. NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Do not attempt clean the old EGR valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3641 EGR Valve: Service and Repair Fig 5 EGR System EGR Mounting NOTE: The EGR valve and Electrical EGR Transducer are serviced as an assembly. REMOVAL 1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for any damage (Fig. 5). 2. Remove electrical connector from solenoid. 3. Remove EGR valve bolts from intake manifold. 4. Open EGR transducer clip and remove electric EGR transducer. 5. Remove EGR valve from intake manifold. 6. Clean gasket surface and discard old gasket. Check for any signs of leakage or cracked surfaces. - Repair or replace as necessary. INSTALLATION 1. Assemble EGR valve with new gasket onto the intake manifold. 2. Install mounting bolts. Tighten bolts to 22 Nm (200 in lb) torque. 3. Install electric EGR transducer in clip with orientation tab in slot and snap closed. 4. Reconnect vacuum hose and electrical connector to electrical EGR transducer. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fill Pipe Restrictor PURPOSE Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter with lead. Flapper controls evaporation of fuel during the time the filler cap is removed. OPERATION The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted. INSPECTION Use dowel gauge to check opening. Look for; tampering, broken flapper, excessive wear etc.. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation > Page 3645 Fillpipe Restrictor: Testing and Inspection Fill Pipe Restrictor Use dowel gauge to check restrictor opening [1]. Inspect for; tampering, broken flapper, excessive wear etc.. Remarks [1] N&W; Manufacturing part number ---> FRG-95, or equivalent, (must be made of non-sparking material, 1552 alloy suggested). - Minimum tool diameter 0.9375" - Maximum tool diameter 0.9500" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Crankcase Filter > Component Information > Description and Operation Crankcase Filter: Description and Operation This engine uses filtered air to vent the crankcase. The filtered air is drawn through the resonator assembly located between the air cleaner and throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Fig 5 PCV Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3653 Positive Crankcase Ventilation Valve: Description and Operation Engine Off Or Engine Backfire - No Vapor Flow The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into combustion chamber based on intake manifold vacuum. When the engine is not operating, or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. High Intake Manifold Vacuum - Minimal Vapor Flow When engine is at idle or cruising, high manifold vacuum is present. At these times, manifold vacuum is able to completely compress spring and pull plunger to top of valve. In this position, there is minimal vapor flow through the valve. Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate intake manifold vacuum, the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3654 Positive Crankcase Ventilation Valve: Testing and Inspection Fig 8 PCV Test -- Typical WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with the engine operating. With the engine idling, remove the PCV valve from its attaching point. If the valve is operating properly, a hissing noise will he heard and a strong vacuum felt when placing a finger over the valve inlet (Fig. 8). With the engine off, shake the valve. The valve should rattle when shaken. - Replace the valve if it does not operate properly. NOTE: Do not attempt to clean the PCV valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 3661 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 3666 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Minimum Air Flow Idle Odometer <= 1000 Miles ................................................................................. .................................................................................................. 525-875 rpm Odometer >= 1000 Miles .................................................................................................................................................... ............................... 575-875 rpm Note: Idle speed range achieved through Minimum Air Flow Idle Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3670 Idle Speed: Testing and Inspection THROTTLE BODY MINIMUM AIR FLOW CHECK Fig 97 Air Metering Fitting 6457 Fig 100 PCV Valve 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457 (0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link connector. 10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. 2.4L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 500-875 RPM Above 1000 Miles 550-875 RPM 3.0L Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 560-910 RPM Above 1000 Miles 610-910 RPM 3.3L/3.8L Idle Specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3671 Odometer Reading Idle RPM Below 1000 Miles 525-875 RPM Above 1000 Miles 575-875 RPM 14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle purge line. 18. Remove DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Specifications Air/Fuel Mixture: Specifications The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal to Dash Nuts .......................................................................................................... ....................................................... 12 Nm (105 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 3678 Accelerator Pedal: Service and Repair Fig 58 Accelerator Pedal And Throttle Cable -- Front View Fig 59 Accelerator Pedal And Throttle Cable -- Rear View CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam. 2. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 58) and (Fig. 59). 3. Working from the engine compartment, remove nuts from accelerator pedal attaching studs (Fig. 58). Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 Nm (105 in lb) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair Fig 125 Air Inlet Resonator REMOVAL 1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner housing halves together. Fig 126 Air Cleaner Housing (Left Side) 3. Remove left side of air cleaner housing (Fig. 126). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3683 Fig 127 Air Cleaner Element 4. Remove element from air cleaner housing (Fig. 127). INSTALLATION 1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4. Install hoses and air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fill Pipe Restrictor PURPOSE Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter with lead. Flapper controls evaporation of fuel during the time the filler cap is removed. OPERATION The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted. INSPECTION Use dowel gauge to check opening. Look for; tampering, broken flapper, excessive wear etc.. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation > Page 3687 Fillpipe Restrictor: Testing and Inspection Fill Pipe Restrictor Use dowel gauge to check restrictor opening [1]. Inspect for; tampering, broken flapper, excessive wear etc.. Remarks [1] N&W; Manufacturing part number ---> FRG-95, or equivalent, (must be made of non-sparking material, 1552 alloy suggested). - Minimum tool diameter 0.9375" - Maximum tool diameter 0.9500" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Recalls: > 743 > Oct > 97 > Recall - Owners Manual Technical Service Bulletin # 743 Date: 971001 Recall - Owners Manual No. 743 October, 1997 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 743 -- Owner's Manual Addendum Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Built Through: ^ July 31, 1997 (MDH 073120) at the Windsor Assembly Plant ("R" in the 11th VIN Position); or ^ August 1, 1997 (MDH 080122) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) Reference: Service Action # 97-28 electronic mail (DMAIL) message on this subject. The enclosed owner notification and Owner's Manual Addendum card are being mailed to all owners of affected 1998 model year minivans. The addendum provides additional information on how to identify those minivans that can be operated on ethanol (E85) fuel. Only minivans equipped with a 3.3L engine (Sales Code -- EGM) and a Federal emission control system (Sales Code -NAA) are capable of operating on ethanol fuel (E85). These vehicles can be identified by the label on the fuel filler door which states "ETHANOL (E85) OR UNLEADED GASOLINE ONLY". Use of E85 in vehicles not designed to use E85, may cause fuel system damage and poor driveability. Dealers are requested to enclose an addendum card in the Owner's Manual of each affected 1998 minivan in dealer stock before retail delivery. Each involved dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough addendum cards (included with the vehicle list) to service 100% of unsold vehicles according to our records. If additional addendum cards are required, dealers may copy and cut out the enclosed addendum card. Owner Letter OWNER'S MANUAL CORRECTION -- ETHANOL (E85) FUEL USAGE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, owners of 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans are being provided with an Owner's Manual Addendum card. A paragraph was inadvertently omitted from your vehicle's Owner's Manual. This omission makes it appear that all 1998 Chrysler minivans are capable of operating on ethanol (E85) fuel. This is incorrect. Only minivans equipped with a 3.3L V-6 engine and a Federal emission control system can be operated on E85. These vehicles can be identified by the label ETHANOL (E85) OR UNLEADED GASOLINE ONLY" on the fuel filler door. Use of E85 in vehicles not designed to use E85 may cause fuel system damage and poor driveability. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Recalls: > 743 > Oct > 97 > Recall - Owners Manual > Page 3696 Please retain the addendum card for future reference. We suggest that you staple it to the appropriate page (listed on the addendum) of your Owner's Manual that is located in the glove box of your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index Fuels Fuel: All Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index Fuels > Page 3702 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 743 > Oct > 97 > Recall - Owners Manual Technical Service Bulletin # 743 Date: 971001 Recall - Owners Manual No. 743 October, 1997 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 743 -- Owner's Manual Addendum Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Built Through: ^ July 31, 1997 (MDH 073120) at the Windsor Assembly Plant ("R" in the 11th VIN Position); or ^ August 1, 1997 (MDH 080122) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) Reference: Service Action # 97-28 electronic mail (DMAIL) message on this subject. The enclosed owner notification and Owner's Manual Addendum card are being mailed to all owners of affected 1998 model year minivans. The addendum provides additional information on how to identify those minivans that can be operated on ethanol (E85) fuel. Only minivans equipped with a 3.3L engine (Sales Code -- EGM) and a Federal emission control system (Sales Code -NAA) are capable of operating on ethanol fuel (E85). These vehicles can be identified by the label on the fuel filler door which states "ETHANOL (E85) OR UNLEADED GASOLINE ONLY". Use of E85 in vehicles not designed to use E85, may cause fuel system damage and poor driveability. Dealers are requested to enclose an addendum card in the Owner's Manual of each affected 1998 minivan in dealer stock before retail delivery. Each involved dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough addendum cards (included with the vehicle list) to service 100% of unsold vehicles according to our records. If additional addendum cards are required, dealers may copy and cut out the enclosed addendum card. Owner Letter OWNER'S MANUAL CORRECTION -- ETHANOL (E85) FUEL USAGE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, owners of 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans are being provided with an Owner's Manual Addendum card. A paragraph was inadvertently omitted from your vehicle's Owner's Manual. This omission makes it appear that all 1998 Chrysler minivans are capable of operating on ethanol (E85) fuel. This is incorrect. Only minivans equipped with a 3.3L V-6 engine and a Federal emission control system can be operated on E85. These vehicles can be identified by the label ETHANOL (E85) OR UNLEADED GASOLINE ONLY" on the fuel filler door. Use of E85 in vehicles not designed to use E85 may cause fuel system damage and poor driveability. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 743 > Oct > 97 > Recall - Owners Manual > Page 3707 Please retain the addendum card for future reference. We suggest that you staple it to the appropriate page (listed on the addendum) of your Owner's Manual that is located in the glove box of your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index Fuels Fuel: All Technical Service Bulletins Engine - High Driveability Index Fuels NO: 14-08-97 GROUP: Fuel DATE: Nov. 21, 1997 SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel MODELS: 1996 - 1998 (AB) Ram Van/Wagon 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (PL) Neon 1997 (PR) Prowler 1996 - 1998 (SR) Viper Roadster/Coupe 1997 - 1998 (TJ) Wrangler 1996 - 1998 (XJ) Cherokee 1995 - 1998 (ZJ) Grand Cherokee SYMPTOM/CONDITION: Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F). DISCUSSION: Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems. For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance. The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular. Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane. Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock. Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index Fuels > Page 3713 contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline. The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction. If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Gasoline Engines Fuel: Specifications Gasoline Engines FUEL REQUIREMENTS The vehicle is designed to meet all emission regulations and provide excellent fuel economy when using high quality unleaded gasoline having a minimum octane rating of 87. The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline will further improve performance. If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful. However; continued heavy spark knock at high speeds can cause damage and should be corrected immediately. Engine damage as a result of heavy spark knock operation may not be covered by the new vehicle warranty. In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended. Using gasoline that has these additives will help improve fuel economy, reduce emissions, and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. ADDITIVES & OXYGENATE BLENDS Additives - The use of gasoline containing detergents, corrosion and stability additives is recommended, as these additives will improve fuel economy, reduce emissions, and maintain vehicle performance. Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you experience these problems, try another brand of gasoline before considering service for the vehicle. Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately. CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered by the new vehicle warranty. GASOLINE/OXYGENATE BLENDS Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other alcohols called cosolvents. CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result in starting and driveability problems and damage critical fuel system components. Problems that are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty. CLEAN AIR GASOLINE MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in those areas of the country where pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as reformulated gasoline.. MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline blended with MTBE may be used in your vehicle. ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17 percent ETBE. Gasoline blended with ETBE may be used in your vehicle. ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials. Indiscriminate use of fuel system cleaning agents should be avoided. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications > Gasoline Engines > Page 3716 Fuel: Specifications Flexible Fuel Engines E-85 GENERAL INFORMATION This information applies only to components or subjects that are specific to Flexible Fuel Vehicles (FFV) only. These vehicles can be identified by the unique Fuel Filler Door Label that states "Ethanol (E-85) or Unleaded Gasoline Only". ETHANOL FUEL (E-85) E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline. WARNING: Ethanol vapors are extremely flammable and could cause serious personal injury. Never have any smoking materials lit in or near the vehicle when removing the fuel filler cap (gas cap) or filling the tank. Do not use E-85 as a cleaning agent and never use E-85 near and open flame. FUEL REQUIREMENTS This vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any mixture of these two fuels. For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be avoided. When you do switch fuels, it is recommended that: You do not switch when the fuel gauge indicates less than 1/4 tank. - You do not add less than 5 gallons when refueling. - You operate the vehicle immediately after refueling for a period of at least 5 minutes. Observing these precautions will avoid possible hard starting and / or significant deterioration in driveablity during warm up. NOTE: When the ambient temperature is above 90°F, you may experience hard starting and rough idle following start-up even if the above recommendations are followed. STARTING The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below 0°F. In the range of 0°F to 32°F, you may experience an increase in the time it takes for your engine to start, and a deterioration in driveability (sags and/or hesitation) until the engine is fully warmed up. CRUISING RANGE Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase in fuel consumption. You can expect your MPG and your driving range to decrease by about 30% compared to gasoline operation. REPLACEMENT PARTS Many components in your Flexible Fuel Vehicle (FFV) are designed to be compatible with ethanol. Always be sure that your vehicle is serviced with correct ethanol compatible parts. CAUTION: Replacing fuel system components with non-ethanol compatible components can damage your vehicle and may void the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Pressure Vent Limit ............................................................................................................................. ................................................ 1.5 psi (10 kPa) Vacuum Vent Limit ................................................... ........................................................................................................................ 1.8 in-Hg (6 kPa) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications > Page 3720 Fuel Filler Cap: Description and Operation Fig 3 Pressure Vacuum Filler Cap A pressure-vacuum relief cap seals the fuel tank (Fig. 3). Tightening the cap on the fuel filler tube forms a seal between them. The relief valves in the cap are a safety feature. They prevent possible excessive pressure or vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the vent lines. The seal between the cap and filler tube breaks when the cap is removed. Removing the cap breaks the seal and relieves fuel tank pressure. The filler cap is also a pressure/vacuum relief valve, which opens whenever pressure in the tank gets either too low or too high. Filler cap venting pressures: Pressure above 10.9 to 13.45 kPa (1.58 to 1.95 psi) - Pressure below 0.97 and 2.0 kPa (0.14 and 0.29 psi) Only filler caps with these specifications may be used as replacements. WARNING: Remove filler cap to relieve tank pressure before removing or repairing fuel system components. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine Fuel Pressure Release: Service and Repair CNG Engine Fuel Line Pressure Release Procedure 1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged. WARNING: The fuel cylinders still contain high-pressure fuel. Fuel Cylinder Pressure Release Procedure 1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4. Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times. WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 3726 Fuel Pressure Release: Service and Repair Gasoline Engine Fig 10 Fuel Pressure Test Port Fig 11 Releasing Fuel Pressure WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. 1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline container. Fuel gauge C-4799-B contains hose C-4799-1. WARNING: Some fuel pressure may still be present in the system. 5. Replace pressure test port cap when finished doing pressure test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Injector resistance should be between 3 and 6 ohms. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3731 Fuel Injector: Pressure, Vacuum and Temperature Specifications Information not supplied by the manufacturer. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3732 Fuel Injector: Locations Fuel Injectors The fuel injectors are attached to the fuel rail which mounts to the lower intake manifold under the air intake plenum. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Flex Fuel Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Flex Fuel > Page 3735 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3736 Fuel Injector: Description and Operation Fig 2 Fuel Injector Fig 3 Fuel Injector Location -- Typical Fuel Injector - Cutaway View The fuel injectors are 12 ohm electrical solenoids (Fig. 2). The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are positioned in the intake manifold. The injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port (Fig. 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3737 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts. For poor fuel economy diagnosis or engine miss, also consider Transmission problems as possible causes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3738 Fuel Injector: Service and Repair Fig 55 Fuel Injector And Rail -- Typical The fuel rail must be removed first. REMOVAL 1. Disconnect injector wiring connector from injector. 2. Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 55). 3. Rotate injector and pull injector out of fuel rail. - The clip will stay on the injector. 4. Check injector 0-ring for damage. - If 0-ring is damaged, it must be replaced. - If injector is reused, a protective cap must be installed on the injector tip to prevent damage. - Replace the injector clip if it is damaged. 5. Repeat for remaining injectors. Fig 57 Servicing Fuel Injector -- Typical INSTALLATION 1. Before installing an injector the rubber 0-ring must be lubricated with a drop of clean engine oil to aid in installation. 2. Install injector clip by sliding open end into the top slot of the injector. - The edge of the receiver cup will slide into the side slots of clip (Fig. 57). 3. Install injector top end into fuel rail receiver cap. - Be careful not to damage 0-ring during installation (Fig. 57). 4. Repeat steps for remaining injectors. 5. Connect fuel injector wiring. CAUTION: Fuel injectors are not interchangeable between engines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Fig 4 Plastic Quick Connect Fittings Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting contains non-serviceable 0-ring seals (Fig. 4). CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged quick-connect fittings or fuel tubes. Replace the complete fuel tube quick-connect fitting assembly. The quick-connect fitting consists of the 0-rings, retainer and casing (Fig. 4). When the fuel tube enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting Fuel Line Coupler: Service and Repair Quick Connect Fitting Fig 12 Plastic Quick-connect Fitting/Fuel Tube Connection When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. Refer to the fuel pressure release procedure. QUICK-CONNECT FITTINGS REMOVAL 1. Disconnect negative cable from battery. 2. Perform Fuel Pressure Release Procedure. - Refer to the Fuel Pressure Release Procedure. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. INSTALLATION 1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer neats and a click is heard. 4. The quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Fig. 12). - Do not rely upon the audible click to confirm a secure connection. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the Ignition switch Is turned to the OFF position. 5. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting > Page 3744 Fuel Line Coupler: Service and Repair Plastic Retaining Ring Type Fitting Fig 13 Plastic Retainer Type Fitting NOTE: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 13) usually black in color. WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Perform Fuel Pressure Release procedure. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. DISCONNECTION/CONNECTION 1. Disconnect negative battery cable from the battery. 2. Perform the fuel pressure release procedure. 3. Clean the fitting of any foreign material before disassembly. 4. To release the fuel system component from the quick-connect fitting: firmly push the fitting towards the component being serviced while firmly pushing the plastic retaining ring into the fitting (Fig. 13) With the plastic ring depressed, pull the fitting from the component. - The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of the plastic retainer ring to aid in disconnection. 5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. - Replace as necessary. 7. Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. - Clean the parts with a lint-free cloth. - Lubricate them with clean engine oil. 8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting ( 15-30 lbs). 10. Connect negative battery cable to battery. 11. Start engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Compressed Natural Gas Engine Fuel Control Valves Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Compressed Natural Gas Engine > Page 3749 Fuel Pressure Regulator: Locations Gasoline Engine Fig 18 Fuel Pressure Regulator The Fuel Pressure Regulator is part of the fuel pump module located in the fuel tank. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3750 Fuel Pressure Regulator: Description and Operation The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 338 kPa (49 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3751 Fuel Pressure Regulator: Adjustments No adjustments available for the fuel system pressure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3752 Fuel Pressure Regulator: Service and Repair Fig 18 Fuel Pressure Regulator The fuel pressure regulator is part of the fuel pump module (Fig. 18). Remove the fuel pump module from the fuel tank to access the fuel pressure regulator. WARNING: Fuel system pressure must be released before servicing any fuel system component. Perform the fuel system pressure release procedure. REMOVAL 1. Spread tangs on pressure regulator retainer (Fig. 18). 2. Pry fuel pressure regulator out of housing. 3. Ensure both upper and lower 0-rings were removed with regulator. Fig 19 Fuel Pressure Regulator O-rings INSTALLATION 1. Lightly lubricate the 0-rings with clean engine oil and place them into opening in pump module (Fig. 19). 2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over tabs on housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3756 Fuel Low Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 3761 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 3768 Fuel Pressure Test Port: Locations Gasoline Fig 1 Intake Plenum Mounting Bolts Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3772 Fuel Pump Relay: Diagrams Fuel Pump Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3773 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3774 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage Technical Service Bulletin # 895 Date: 020101 Recall - Potential Fuel Rail Seal Leakage January 2002 Dealer Service Instructions for Safety Recall No. 895 -- Fuel Rail Seals Models 1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or "L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999). IMPORTANT: Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in this recall. IMPORTANT: Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire. Repair External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3783 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3784 Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD895". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by describing the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Fuel Rail 1. Raise hood. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3785 2. Inspect both of the fuel rail crossover tube joints (Figure 1) 3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. > If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube joints, continue with Section B - Install Fuel Rail Seals. B. Install Fuel Rail Seals 1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3786 2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles. 3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease seal installation. 4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads. IMPORTANT: Drain any excess oil from the seals. 5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3). NOTE: Both of the seal halves are identical. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3787 6. Seat the seal halves around the joint and then while holding the two seals halves together, install one of the provided clamps around the seal halves (Figure 4). 7. Tighten the clamp to 75 in-lbs (8.5 N.m). 8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3). 9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4). 10. Tighten the clamp to 75 in-lbs (8.5 N.m). 11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows: a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip. b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3788 c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely. 12. No further action is necessary. Return the vehicle to the customer. C. Replace Fuel Rail Assembly NOTE: Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement. WARNING: The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail. 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure. 3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail. 4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure. 5. Remove the hose from the fuel rail and reinstall the test port cap. 6. Remove the plastic intake manifold cover, if equipped. 7. Remove the air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3789 8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7). 9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8). 10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3790 11. Disconnect the EGR tube from the intake manifold flange (Figure 10). 12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head. 13. Disconnect the MAP sensor electrical connector (Figure 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3791 14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12). WARNING: Wrap a shop towel around the hoses to catch any gasoline spillage. 15. Remove the Direct Ignition System (DIS) coil pack (Figure 13). 16. Remove the generator support bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3792 17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve cover (Figure 14). NOTE: It is not necessary to completely remove the intake plenum from the vehicle. 18. Cover the intake manifold openings. 19. Remove the fuel rail attaching bolts (Figure 15). 20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 21. Disconnect the fuel rail wiring harness from the main engine harness. 22. Remove the fuel rail assembly. 23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are easily accessible. 24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3793 25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17). 26. Remove the upper and lower injector 0-rings from the injectors. 27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil. 28. Install the new upper 0-rings (BLUE) on the top of the injectors. CAUTION: Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result. 29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil. 30. Install the new lower 0-rings (BLACK) on the bottom of the injectors. 31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector. 32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper 0-ring is not damaged during installation. 33. Connect the injector wiring harness to the injectors. 34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port. 35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N.m). 36. Connect the fuel injector wiring harness to the main engine wiring harness. 37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection. 38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces. 40. Place the provided intake plenum gasket on the intake manifold. 41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum bolts. Do NOT tighten. 42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3794 43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten. 44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten. 45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N.m). 46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m). 47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m). 48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10). 49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm). 50. Connect the MAP sensor electrical connector (Figure 11). 51. Connect the vacuum hoses to the intake plenum (Figure 9). 52. Connect the TPS and idle air control motor electrical connectors (Figure 8). 53. Connect the throttle body vacuum connectors (Figure 9). 54. Connect the throttle cable and speed control cable (if equipped) (Figure 7). 55. Install the intake manifold cover (if equipped). 56. Install the air inlet resonator. 57. Connect the negative battery cable. 58. Start the engine and check for any fuel leakage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal Leakage > Page 3795 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Recalls for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000: Fuel Rail Cracks/Leaks Fuel Rail: Recalls Recall 00V268000: Fuel Rail Cracks/Leaks Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing O-rings continue to degrade. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage Technical Service Bulletin # 895 Date: 020101 Recall - Potential Fuel Rail Seal Leakage January 2002 Dealer Service Instructions for Safety Recall No. 895 -- Fuel Rail Seals Models 1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or "L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999). IMPORTANT: Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in this recall. IMPORTANT: Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty records, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire. Repair External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3805 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3806 Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required Dealer Notification All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD895". Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Vehicle Not Available If a vehicle is not available for service, let us know by describing the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation A. Inspect Fuel Rail 1. Raise hood. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3807 2. Inspect both of the fuel rail crossover tube joints (Figure 1) 3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. > If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly. If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube joints, continue with Section B - Install Fuel Rail Seals. B. Install Fuel Rail Seals 1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3808 2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles. 3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease seal installation. 4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads. IMPORTANT: Drain any excess oil from the seals. 5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3). NOTE: Both of the seal halves are identical. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3809 6. Seat the seal halves around the joint and then while holding the two seals halves together, install one of the provided clamps around the seal halves (Figure 4). 7. Tighten the clamp to 75 in-lbs (8.5 N.m). 8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3). 9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4). 10. Tighten the clamp to 75 in-lbs (8.5 N.m). 11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows: a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip. b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3810 c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely. 12. No further action is necessary. Return the vehicle to the customer. C. Replace Fuel Rail Assembly NOTE: Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement. WARNING: The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail. 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure. 2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure. 3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6). WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail. 4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure. 5. Remove the hose from the fuel rail and reinstall the test port cap. 6. Remove the plastic intake manifold cover, if equipped. 7. Remove the air inlet resonator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3811 8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7). 9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8). 10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3812 11. Disconnect the EGR tube from the intake manifold flange (Figure 10). 12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head. 13. Disconnect the MAP sensor electrical connector (Figure 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3813 14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12). WARNING: Wrap a shop towel around the hoses to catch any gasoline spillage. 15. Remove the Direct Ignition System (DIS) coil pack (Figure 13). 16. Remove the generator support bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3814 17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve cover (Figure 14). NOTE: It is not necessary to completely remove the intake plenum from the vehicle. 18. Cover the intake manifold openings. 19. Remove the fuel rail attaching bolts (Figure 15). 20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 21. Disconnect the fuel rail wiring harness from the main engine harness. 22. Remove the fuel rail assembly. 23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are easily accessible. 24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3815 25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17). 26. Remove the upper and lower injector 0-rings from the injectors. 27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil. 28. Install the new upper 0-rings (BLUE) on the top of the injectors. CAUTION: Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result. 29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil. 30. Install the new lower 0-rings (BLACK) on the bottom of the injectors. 31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector. 32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper 0-ring is not damaged during installation. 33. Connect the injector wiring harness to the injectors. 34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port. 35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N.m). 36. Connect the fuel injector wiring harness to the main engine wiring harness. 37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection. 38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16). 39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces. 40. Place the provided intake plenum gasket on the intake manifold. 41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum bolts. Do NOT tighten. 42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3816 43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten. 44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten. 45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N.m). 46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m). 47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m). 48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10). 49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm). 50. Connect the MAP sensor electrical connector (Figure 11). 51. Connect the vacuum hoses to the intake plenum (Figure 9). 52. Connect the TPS and idle air control motor electrical connectors (Figure 8). 53. Connect the throttle body vacuum connectors (Figure 9). 54. Connect the throttle cable and speed control cable (if equipped) (Figure 7). 55. Install the intake manifold cover (if equipped). 56. Install the air inlet resonator. 57. Connect the negative battery cable. 58. Start the engine and check for any fuel leakage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3817 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000: Fuel Rail Cracks/Leaks Fuel Rail: All Technical Service Bulletins Recall 00V268000: Fuel Rail Cracks/Leaks Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail. Fuel leakage in the presence of an ignition source can result in a fire. Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel rail crossover tube, should the existing O-rings continue to degrade. DaimlerChrysler has not yet provided NHTSA with an owner notification schedule. However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3822 Fuel Rail: Specifications Fuel Rail Bolt ....................................................................................................................................... ....................................................... 10 Nm (95 in lb) Fuel Tube Holddown Screw ................................................................................................................ .......................................................... 4 Nm (35 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3823 Fuel Rail: Description and Operation Fuel Rail The fuel rail is a steel distribution pipe with mounting points for the fuel pressure regulator, 6 fuel injectors, and injector wire harness. The fuel rail performs the dual functions of fuel supply to the injection components, and providing the necessary brackets and fittings to mount the components to the engine. Fuel enters the fuel rail at the inlet tube, proceeds to the 6 fuel injectors and fuel pressure regulator, and returns to the tank via the fuel return line. The fuel rail is under constant fuel pressure and fuel pressure release is required prior to servicing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3824 Fuel Rail: Service and Repair Fig 37 Air Inlet Resonator Fig 44 Throttle Cable Attachment WARNING: The fuel system is under a constant pressure of approximately 330 kPa (49 psi). Perform fuel pressure release procedure before servicing the fuel rail or fuel injectors. REMOVAL 1. Perform fuel system pressure release procedure. 2. Disconnect negative cable from battery. 3. Remove intake manifold cover. 4. Remove air inlet resonator (Fig. 37). 5. Remove throttle cable and speed control cable (if equipped) (Fig. 44) from throttle lever and bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3825 Fig 45 Electrical And Vacuum Connection To Throttle Body 6. Disconnect idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Fig. 45). Fig 46 Vacuum Connections 7. Remove vacuum hose harness from throttle body and intake manifold (Fig. 46). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3826 Fig 47 EGR Tube 8. Remove EGR tube to intake manifold flange bolts (Fig. 47). 9. Remove cylinder head to intake plenum strut. Fig 48 MAP Connector 10. Disconnect electrical connector from the MAP sensor (Fig. 48) 11. Remove engine mounted ground strap. Fig 49 Fuel Line Quick Disconnect 12. Remove the fuel hose quick connect fitting from the chassis tube (Fig. 49). WARNING: Wrap a shop towel around hoses to catch any gasoline spillage. Fig 50 Ignition Coils Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3827 13. Remove Direct Ignition System (DIS) coils (Fig. 50). 14. Remove generator bracket to intake manifold bolt. Fig 51 Intake Manifold Bolts 15. Remove intake mounting manifold bolts and rotate manifold back over rear valve cover (Fig. 51). Fig 52 Fuel Rail Attaching Bolts 16. Cover intake manifold with suitable cover when servicing (Fig. 52). 17. Remove fuel tube retainer bracket screw and fuel rail attaching bolts (Fig. 52). Spread the retainer bracket to allow fuel tube removal clearance. Fig 53 Camshaft Position Sensor Connector 18. Disconnect camshaft position sensor (Fig. 53) and engine coolant temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 3828 Fig 54 Fuel Rail Removal 19. Remove fuel rail. Be careful not to damage the injector 0-rings upon removal from their ports (Fig. 54). INSTALLATION 1. Ensure injector holes are clean. Replace 0-rings if damaged. 2. Lubricate injector 0-rings with a drop of clean engine oil to ease installation. 3. Put the tip of each injector into their ports. - Push the assembly into place until the injectors are seated in the ports. 4. Install the fuel rail mounting bolts. - Tighten bolts to 22 Nm (200 in lb) torque (Fig. 52). 5. Install fuel tube retaining bracket screw. - Tighten screw to 4 Nm (35 in lb) torque. 6. Connect electrical connectors to camshaft position sensor and engine coolant temperature sensor. 7. Remove covering on lower intake manifold and clean surface. 8. Place intake manifold gasket on lower manifold. - Put upper manifold into place and install bolts finger tight. 9. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts - Do not tighten. 10. Following the tightening sequence in (Fig. 51), tighten intake manifold bolts to 28 Nm (250 in lb) torque. 11. Tighten generator bracket to intake manifold bolt to 54 Nm (40 ft lb) torque. 12. Tighten the cylinder head to intake manifold strut bolts to 54 Nm (40 ft lb) torque. 13. Connect ground strap and MAP sensor electrical connector. 14. Connect vacuum harness to intake plenum. Connect PCV system hoses. 15. Using a new gasket, connect the EGR tube to the intake manifold plenum. - Tighten screws to 22 Nm (200 in lb) torque. 16. Connect electrical connectors to the TPS and idle air control motor. 17. Connect vacuum harness to throttle body. 18. Install the Direct Ignition System (DIS) coils. - Tighten fasteners to 12 Nm (105 in lb) torque. 19. Install fuel hose quick connector fitting to chassis tubes. - Push the fitting onto the chassis tube until it clicks into place. - Pull on the fitting to ensure complete insertion. 20. Install throttle cable and speed control cable (if equipped). 21. Install air inlet resonator. 22. Connect negative cable to battery. CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Oft position. 23. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Locations Fuel Pump Module Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Locations Fuel Pump Module Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 3839 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3843 Fuel Temperature Sensor Connector CNG Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control Motor ........................................................................................................................... ....................................................... 2 Nm (18 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations Idle Speed/Throttle Actuator - Electronic: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3849 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3852 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3853 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3854 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3855 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3856 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3857 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3858 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3859 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3860 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3861 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3862 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3863 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3864 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3865 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3866 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3867 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3868 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3869 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3870 Idle Air Control Moor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3871 Idle Air Control Motor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3872 Idle Speed/Throttle Actuator - Electronic: Description and Operation PURPOSE Maintains optimum idle speed under varying engine loads. Prevents deceleration die out. OPERATION Powertrain Control Module (PCM) calculates proper idle speed using information from throttle position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches. PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body. Prevents decel die out by increasing air flow when throttle is closed suddenly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3873 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool. CAUTION: Proper safety precautions must be taken when testing the IAC motor. - Set the parking brake and block the drive wheels - Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust components - Provide proper ventilation while operating the engine - Always return the engine idle speed to normal before disconnecting the exerciser tool. - Follow scan tool manufacturer's instructions for testing the IAC motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3874 Idle Speed/Throttle Actuator - Electronic: Service and Repair Fig 109 Servicing Idle Air Control Motor NOTE: When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. - Never use lubricants on 0-rings or seals, damage may result. - If assembly of component is difficult, use water to aid assembly. - Use care when removing hoses to prevent damage to hose or hose nipple. REMOVAL 1. Disconnect negative cable from battory; 2. Remove electrical connector from idle air control motor. 3. Remove idle air control motor mounting screws (Fig. 109). 4. Remove motor from throttle body. Ensure the 0-ring is removed with the motor. INSTALLATION 1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the DRB Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.) 2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten screws to 2 Nm (17 in lb) torque. 4. Connect electrical connector to idle air control motor. 5. Connect negative cable to battery Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Component Information > Specifications Intake Air Plenum: Specifications Support Bracket Fastener .................................................................................................................... ...................................................... 54 Nm (40 ft. lbs.) Bolts ................................................................ .................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3883 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3884 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3885 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3886 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3887 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3888 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3889 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3890 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3891 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3892 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3893 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3894 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3895 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3896 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3899 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3900 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3901 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3902 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3905 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3910 Fuel Pump Relay: Diagrams Fuel Pump Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3911 Fuel Pump Relay: Testing and Inspection Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3912 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions Automatic Shut Down (ASD) Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3918 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3919 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3920 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3921 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3922 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3923 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3924 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3925 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3926 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3927 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3928 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3929 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3930 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3931 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3932 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 Automatic Shut Down (ASD) Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 Automatic Shut Down (ASD) Relay: Connector Views Auto Shutdown Relay Connector Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3937 Automatic Shut Down (ASD) Relay: Description and Operation Fig 5 Power Distribution Center PURPOSE The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating elements in the oxygen sensors. OPERATION The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the ground path on and off. The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02 Heater Monitor test is being run. - When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil dwell). If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals when the ignition switch is in the Run position, it will de-energize the ASD relay. The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the relays and fuses in the PDC. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay Fig. 29 ASD And Fuel Pump Relay Terminals Fig 77 ASD And Fuel Pump Relay Terminals Fig 78 ASD And Fuel Pump Relay Terminals Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3940 NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be tested using this procedure. The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29). OPERATION Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump relay. Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through terminal number 85. Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity. OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the OFF position. - Terminal 87A is the center terminal on the relay. - There is no wire or terminal in the cavity. In the OFF position voltage is not supplied to the rest of the circuit. ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the ON position. - Terminal 87 supplies voltage to the rest of the circuit. TEST 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should be between 70 to 80 ohms. 3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt power source. DO NOT attach the other end of the jumper wire to the relay at this time. WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. - The ohmmeter SHOULD show continuity between relay terminals 87 and 30. - The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to electrical diagrams. NOTE: Other testing for this system or component is done at the system level. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble Codes) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation This vehicle has 2 rollover valves on top of the fuel tank. These valves prevent prevent fuel flow through the fuel tank vent valve hoses should the vehicle roll over. The rollover valves on the fuel tank are not serviceable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3948 Fuel Low Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3952 Fuel Temperature Sensor Connector CNG Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3957 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3958 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3959 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3960 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3961 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3962 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Bolts .............................................................................................................................. ..................................................... 26 Nm (225 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3966 Throttle Body: Description and Operation Fig 43 Throttle Body The throttle body is located on the left side of the intake manifold plenum. The throttle body houses the throttle position sensor and the idle air control motor. Air flow through the throttle body is controlled by a cable operated throttle blade located in the base of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3967 Throttle Body: Testing and Inspection Fig 97 Air Metering Fitting 6457 Fig 100 PCV Valve 1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2. Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457 (0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link connector. 10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one 180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The following will then occur: - Idle air control motor will fully close. - Idle spark advance will become fixed. - DRB scan tool displays engine rpm. 13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum airflow is set correctly. Idle Specifications Odometer Reading Idle RPM Below 1000 Miles 525-875 RPM Above 1000 Miles 575-875 RPM 14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows: a. Remove the throttle body from engine. WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash thoroughly after using cleaner. b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner. Only use Mopar Parts Cleaner to clean the throttle body. c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and manifold side of the throttle blade. The edges of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3968 throttle blade and portions of the throttle bore that are closest to the throttle blade when closed, must be free of deposits. d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f. Install throttle body on manifold. g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is not caused by the throttle body. 15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle purge line. 18. Remove DRB scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning Throttle Body: Service and Repair Throttle Body Cleaning WARNINGS: ^ Clean throttle body in a well ventilated area. ^ Wear proper eye protection. ^ Wear rubber or butyl gloves when using parts cleaner. ^ Avoid ingesting cleaner. ^ Wash thoroughly after using cleaner. PURPOSE The throttle body is designed to have a gap between the throttle plate and the throttle bore, at closed throttle (idle), for minimum air flow operation. It is common for deposits to form in the throttle body and intake plenum. Deposits on the throttle plate, and throttle bore, which reduce the minimum air flow gap, can cause idle and driveability problems, (stalling at stops, rough or unstable idle), that may or may not set a Diagnostic Trouble Code (DTC). EXAMPLE: If the minimum air flow gap is reduced enough by deposits, and the throttle plate is closed suddenly (deceleration), the Idle Air Control (IAC) motor cannot adjust fast enough to compensate for the sudden lack of air, and the vehicle stalls. INSPECTION Visually inspect the throttle body for cracks, deformation or tampering. Replace throttle body if there are any signs damage. CLEANING PROCEDURE 1. Remove the throttle body. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES. CAUTION: Do not use harsh abrasives or tank solvent washing to clean the throttle body. 2. While holding the throttle open, spray the entire throttle body bore and throttle plate with suitable cleaner. 3. Using a soft scuff pad, clean the throttle body bore and throttle blade (front, back and edges). It is critical that the edges of the throttle blade, and the portion of the throttle bore that are close to the throttle blade when it is closed, are free of deposits. 4. Inspect the intake plenum, and clean, if deposits are visible. 5. Install throttle body, and perform throttle body minimum airflow test. SEE DIAGNOSIS, TESTING AND INSPECTION PROCEDURES NOTES: If vehicle is difficult to start after cleaning throttle body, it may be necessary to reset adaptive memory. SEE Powertrain Management/ Computers and Control Systems/Testing and Inspection/Procedures. If minimum air flow idle speed is still not within specifications, after cleaning the throttle body, and the throttle body shows no signs of physical damage, the problem is not caused by the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 3971 Throttle Body: Service and Repair Throttle Body Replacement Throttle Body Removal And Replacement REMOVAL 1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. 3. Remove 2 screws and air inlet resonator. Fig 102 Throttle Cable Attachment To Throttle Body 4. Remove throttle and the speed control (if equipped) cables from lever and bracket (Fig. 102). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Cleaning > Page 3972 Fig 105 Throttle Body Electrical And Vacuum Connections 5. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS) (Fig. 105). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake manifold attaching nuts. 8. Remove throttle body and gasket. INSTALLATION 1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in lb) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair Fig 62 Throttle Cable To Throttle Body Attachment CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not damage or kink the core wire inside the cable sheathing. REMOVAL 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. 2. Remove the throttle cable from the throttle body cam (Fig. 60), (Fig. 61) and (Fig. 62). Fig 58 Accelerator Pedal And Throttle Cable -- Front View 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft (Fig. 58). Fig 59 Accelerator Pedal And Throttle Cable -- Rear View 4. Remove retainer clip from throttle cable and grommet at dash panel (Fig. 59). 5. From the engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should remain in the dash panel. 6. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously Then gently pull the throttle cable Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Page 3976 from throttle bracket. INSTALLATION 1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet (Fig. 59) 5. From the engine compartment, rotate the throttle lever wide open and install the throttle cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations Throttle Position Sensor: Component Locations Throttle Body View With Idle Air Control Motor Idle Air Control Motor And Throttle Position Sensor Mounted on throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3981 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3982 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3983 Throttle Position Sensor: Description and Operation PURPOSE PCM uses sensor input with other inputs to determine current operating conditions. PCM adjusts air/fuel mixture (injector pulse width) and ignition timing. OPERATION The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. - As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts at wide open throttle. The TPS mounts to the side of the throttle body. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3984 Throttle Position Sensor: Testing and Inspection To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool and follow the appropriate procedures. To test the throttle position sensor only, refer to the following: The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the remaining terminal is ground. Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for correct pinout. With the ignition switch in the ON position, check the output voltage at the center terminal wire of the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts. - At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts. - The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT. NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3985 Throttle Position Sensor: Adjustments PROCEDURE - The Throttle Position Sensor on this vehicle is fixed and adjustment is not required. - If sensor output voltage is outside acceptable range, sensor should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3986 Throttle Position Sensor: Service and Repair Fig 108 Servicing Throttle Position Sensor REMOVAL 1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off throttle shaft (Fig. 108). INSTALLATION 1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm (17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Firing Order Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Locations Timing Marks and Indicators: Locations This vehicle is not equipped with timing marks. However spark advance can be monitored using a DRBII or equivalent scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4002 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4003 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4026 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4027 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4028 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4029 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4030 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4034 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4045 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4046 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4047 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4048 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4049 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4050 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4051 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4052 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4053 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4054 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4055 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4056 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4057 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4058 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4059 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4060 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications Ignition Cable: Specifications Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 4064 Ignition Cable: Description and Operation NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires". PURPOSE Transfer electrical current from the coil to the individual spark plugs at each cylinder. Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition system. CONSTRUCTION The spark plug cables and spark plug boots are made from high temperature silicone materials. Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust manifold. The heat shields slide over the spark plug boots. - The notches on the heat shields ensure the spark plug boot and shield twist together during spark plug boot removal. - They also identify proper heat shield installation on the boot for service. - All spark plug cable leads are properly identified with cylinder numbers. Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure. - Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent or missing. - Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems. - The bottom of the spark plug heat shield must make contact with the spark plug hex. Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone grease for greater sealing and to minimize boot bonding to the spark plug insulator. The convoluted tubing on the rear plug cables are made of a high temperature plastic material. Service Life Under normal driving conditions, the spark plug cables have a recommended service life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions. CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable must not touch the coil mounting bolt to avoid abrasion/dielectric failures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Ignition Cable: Initial Inspection and Diagnostic Overview INSPECTION Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower, distributor tower or spark plug insulator. NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter cable service life. To maintain proper sealing at terminal connections, do not disconnect cables. This should only be done when testing. Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4067 Ignition Cable: Component Tests and General Diagnostics Secondary Ignition Cable Insulation Test CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during testing. Excessive heat could damage the catalytic converter. - Total test time must not exceed ten minutes. CAUTION: To maintain proper sealing at the terminal connections, the connections should not be broken unless testing indicates high resistance, an open circuit or other damage. INSPECTION Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good condition. Covers should fit tightly on the coil pack and spark plug insulators. Cable connections that are loose will corrode and increase the resistance and permit water to enter the towers causing ignition malfunction. INSULATION TEST NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be tested as follows: 1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated alligator clips on each end) to a good ground, other end free for probing. 2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8 inch gap). If punctures or cracks are present there will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same way. 3. Replace ALL cracked, leaking or faulty cables. Secondary Ignition Cable Resistance Test Cable ................................................................................................................................................... .............................................. Maximum Resistance #1 ......................................................................................................................................................... ............................................................ 18.5k ohms #2 ......................................................................................................................................................... ............................................................ 15.5k ohms #3 ......................................................................................................................................................... ............................................................ 20.4k ohms #4 ......................................................................................................................................................... ............................................................ 21.2k ohms #5 ......................................................................................................................................................... ............................................................ 27.7k ohms #6 ......................................................................................................................................................... ............................................................ 26.7k ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Replacing Cables Ignition Cable: Service and Repair Replacing Cables Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause sever injury/burns and can cause damage to the ignition cables. CAUTIONS: - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly. - Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield must make contact with the spark plug socket hex. - Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can damage the ignition cable conductor. SPARK PLUG CABLES #3 AND #5 Removal 1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the spark plug. - Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the retaining bracket. - Make sure that they are also detached from the rear retaining clip mounted on the rear of the intake manifold. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 3. Install the resonator. SPARK PLUG CABLE #1 Removal 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal with the plug and pull straight back. CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, or the cable insulation. 5. Wipe spark plug insulator clean with a dry cloth before installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 4070 6. Remove the cable from the retaining bracket. Installation 1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals are fully seated. - A click sound should be heard or terminal engagement is felt when the terminals are properly attached. 2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install the accessory drive belt, refer to Cooling System. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair > Replacing Cables > Page 4071 Ignition Cable: Service and Repair Cleaning Cables Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Ignition Coil: Customer Interest Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4080 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4081 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4082 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4083 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Ignition Coil: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4089 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4090 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4091 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 4092 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Coil Polarity IGNITION COIL RESISTANCE @ 21°C-27°C (70°F-80°F) Coil Manufacture Primary Resistance Secondary Resistance Weastec 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms (Aluminum Towers) Diamond Electric 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms (Brass Towers) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 4095 Ignition Coil: Mechanical Specifications Ignition Coil .......................................................................................................................................... ........................................... 12 Nm (105 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations Ignition Coil: Component Locations Ignition Coil And Coolant Temperature Sensor Location Coil pack mounted on intake manifold, above thermostat housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Component Locations > Page 4098 Ignition Coil Electrical Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4099 Fuel Injectors Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4100 Coil Polarity Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4101 Ignition Coil: Description and Operation Fig 4 Coil Pack WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could result from contact with this system. CONSTRUCTION The ignition coil assembly consists of independent coils molded together (Fig. 4). The coil assembly is mounted on the intake manifold. Spark plug cables route to each cylinder from the coil. OPERATION The coil fires two spark plugs every power stroke. One plug is the cylinder under compression. - The other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the correct time. Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5 and coil 3 fires cylinders 3 and 6. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the coil primary transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4102 Ignition Coil: Testing and Inspection Fig 18 Ignition Coil Electrical Connector Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, and coil 3 fires cylinders 3 and 6. Each coil tower is labeled with the number of the corresponding cylinder. 1. Disconnect the electrical connector from the coil pack (Fig. 18). Fig 19 Ignition Coil Terminal ID 2. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+ pin and the pin corresponding to the cylinders in question (Fig 19). Resistance on the primary side of each coil should be 0.45 - 0.65 ohm at 21° to 27°C (70° to 80°F). - A coil that has not been allowed to cool off, would result in inaccurate measurement results. - Replace the coil if resistance is not within tolerance. Fig 20 Checking Ignition Coil Secondary Resistance 3. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil (Fig. 20). Secondary resistance should be 7,000 to 15,800 ohms. - Replace the coil if resistance is not within tolerance. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4103 Ignition Coil: Service and Repair Fig 2 Ignition Coil Removal REMOVAL 1. Remove spark plug cables from coil (Fig. 2). - Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot. 2. Remove ignition coil electrical connector. 3. Remove ignition coil mounting screws. 4. Remove ignition coil. INSTALLATION 1. Reverse the above procedure for installation. - Tighten mounting screws to 12 Nm (105 in lb) torque. 2. Transfer spark plug cables to new coil pack. - The coil pack towers and cables are numbered with the cylinder identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4107 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4108 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4109 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4110 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications Camshaft Position Sensor: Electrical Specifications Slot Sensed ......................................................................................................................................... .............................................. approximately 5.0 Volts No Slot Sensed .............................................. ................................................................................................................................... approximately 0.3 Volts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4116 Camshaft Position Sensor: Mechanical Specifications Camshaft Position sensor screw ......................................................................................................... ....................................................... 14 Nm (125 in lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4117 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4120 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4121 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Camshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4136 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4137 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4138 Camshaft Position Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4139 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4140 Camshaft Position Sensor: Description and Operation Fig 9 Camshaft Position Sensor PURPOSE - Sensor provides PCM with cylinder identification. - PCM uses sensor input to determine fuel injection sequence and ignition timing. Fig 10 Camshaft Sprocket OPERATION The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 10). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4141 Fig 11 Camshaft Position Sensor The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4142 Camshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4143 Camshaft Position Sensor: Service and Repair Fig 5 Camshaft Position Sensor REMOVAL 1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig. 5). Fig 6 Camshaft Sensor Bolt Removal/Installation 2. Remove bolt holding sensor (Fig. 6). - There is a hole in the bracket for tool access to the sensor bolt. Fig 7 Camshaft Sensor Removal/Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 4144 3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover. - Do not pull on the sensor lead. - There is an 0-ring on the sensor case. The 0-ring may make removal difficult. - A light tap to top of sensor prior to removal may reduce force needed for removal. Fig 8 Camshaft Position Sensor And Spacer NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and 0- ring is positioned in groove of the new sensor (Fig. 8). INSTALLATION 1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. - While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb) torque. 4. Connect camshaft position sensor electrical connector to harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications Crankshaft Position Sensor: Specifications Crankshaft Position sensor screw .............................................................................................................................................................. 12 Nm (105 in lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4148 Crankshaft Position Sensor: Locations Crankshaft Position Sensor The Crankshaft Position Sensor is mounted on the transaxle bellhousing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4151 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4152 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4153 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4154 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4155 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4156 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4157 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4158 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4159 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4160 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4161 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4162 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 Crankshaft Position Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Crankshaft Position Sensor Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4171 Crankshaft Position Sensor: Description and Operation Fig 6 Crankshaft Position Sensor Fig 7 Timing Slots Fig 8 Crankshaft Position Sensor OPERATION The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7). There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. The crankshaft sensor is located on the passengers side of the transmission housing, above the differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate. CIRCUIT OPERATION Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position sensor. The K7 circuit originates at cavity 44 of Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4172 the PCM connector. Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity 32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit K24 splices to the transmission control module. The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity 43 of the PCM. Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor. Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor - Downstream heated oxygen sensor - Camshaft position sensor - Throttle position sensor - Manifold absolute pressure sensor - Engine coolant temperature sensor - Knock sensor - Intake air temperature sensor - Vehicle speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4173 Crankshaft Position Sensor: Testing and Inspection The output voltage of a properly operating camshaft position sensor or crankshaft position sensor switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS) and engine analyzer to the vehicle, technicians can view the square wave pattern. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4174 Crankshaft Position Sensor: Service and Repair Fig 4 Crankshaft Position Sensor Connector Fig 5 Crankshaft Position Sensor And Spacer REMOVAL 1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull crankshaft position sensor straight up out of the transaxle housing. NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the sensor face before installation. If the sensor is being replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5). INSTALLATION 1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While holding the sensor in this position, and install and tighten the retaining bolt to 11.9 Nm (105 in lb) torque. 2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the wiring harness connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4184 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 4190 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4191 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4192 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4196 Map Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4197 Knock Sensor: Description and Operation PURPOSE When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. OPERATION The knock sensor threads into the side of the cylinder block in front of the starter motor. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. - As the intensity of the crystal's vibrations increase, the knock sensor output voltage also increases. CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper spark control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4198 Knock Sensor: Testing and Inspection The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing - Cylinder Pressure - Fuel Octane etc The knock generates an AC voltage whose amplitude increases with increasing engine knock. The knock sensor can be tested with a digital voltmeter. The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately 600mVAC (5,000 rpm). If the output falls outside of this range a DTC will be set. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4199 Knock Sensor: Service and Repair Fig 12 Knock Sensor NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12). REMOVAL 1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the knock sensor. INSTALLATION 1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque. CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper spark control. 2. Attach electrical connector to knock sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Electrode Gap ...................................................................................................................................... .................................. 1.21-1.34 mm (0.048-0.053 in) Torque ............................................................. .............................................................................................................................................. 28 Nm (20 ft lb) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4203 Spark Plug: Service Precautions CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4204 Spark Plug: Application and ID Spark Plug ........................................................................................................................................... ............................................................... RN14PMP5 Thread ............................................................. ................................................................................................................................................ (14mm) 3/4 in. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4205 Spark Plug: Description and Operation Fig 3 Platinum Plug Pads NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a recommended service life of 100,000 miles for normal driving conditions. The recommended service life under severe conditions is 75,000 miles. - A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3). - Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss, decrease in engine speed, hard starting and, in general, poor engine performance. Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken insulator. CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs. This would damage the platinum pads which would shorten spark plug life. Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's original spark plugs that have been determined good. - Do not apply anti-seize compound to new spark plugs. NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied correctly. It is extremely important that the anti-seize compound does not make contact with the spark plug electrodes or ceramic insulator. Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the procedures. Due to the engine packaging environment for this engine, extreme care should be used when installing the spark plugs to avoid cross threading problems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4208 Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4209 Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4210 Spark Plug: Testing and Inspection Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4211 Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator Chipped Electrode Insulator NOTE: Replace any spark plugs which have cracked broken or chipped insulators. Symptoms: Insulator chipped or broken. Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap. - Severe detonation also can separate the insulator from the center electrode. - Sudden Rise In Tip Temperature. - Severe Operating Conditions. - Improper Gapping Of Plugs. Brown to Gray/Tan Color - Normal Operating Condition DESCRIPTION: Brown to greyish-tan deposits and slight electrode wear. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Normal wear ^ Clean, regap, and install, if wear is not excessive .............................................................................................................................................................. .................................................................................... Dry, Fluffy Black Deposits - Cold or Carbon Fouling Normal Operation And Carbon Fouling Symptoms: Dry, black deposits on the electrodes. Possible Causes: - On one or two plugs, may be caused by sticking valves or defective spark plug cables. - On the entire set, may be caused by a clogged air cleaner. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4212 - Poor Ignition Output NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs do not reach a high enough operating temperature during short operating periods to burn fuel completely. Electrode Gap Bridging Electrode Gap Bridging Symptoms: Gap between the electrodes bridged by deposits. Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load, the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the electrodes. NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures. Heavy Colored Deposits DESCRIPTION: Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on the side facing the intake valve. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap, and reinstall .............................................................................................................................................................. .................................................................................... Oil or Ash Encrusted Oil Or Ash Encrusted Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4213 Symptoms: Electrodes encrusted with dry oil or ash. Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber. Premature Electrode Wear - Preignition Damage Preignition Damage Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later. Insulators appear relatively deposit free. Possible Causes: Excessive combustion chamber temperature. - Incorrect spark plug heat range [1]. - Ignition timing is over advanced - Other operating conditions are causing engine overheating. [1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat range. Variations in thickness and length of the center electrode and porcelain insulator change how fast the plug can dissipate heat and determine the plugs heat range. Red, Brown, Yellow or White Deposits - Fuel Additives Scavenger Deposits Symptoms: Red, Brown, White or Yellow deposits. Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of deposits and decrease spark plug misfire tendencies. NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in condition and be cleaned using standard procedures. Shiny Yellow Glaze DESCRIPTION: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 4214 Shiny yellow glaze coating on the insulator. POSSIBLE CAUSE ACTION .............................................................................................................................................................. .................................................................................. Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long periods of low speed driving. .............................................................................................................................................................. .................................................................................... Spark Plug Inspection - Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance Schedules. - Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The spark plug gap is 0.89 mm (0.035 in). - Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap. Spark Plug Resistance Test Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. Wet Oily Deposits Symptoms: Electrodes coated with excessive wet fuel or oil. Possible Causes: - In older engines, wet fouling can be caused by worn rings or excessive cylinder wear. - In new or recently overhauled engines, fouling may occur before normal oil control is achieved. Break-in fouled spark plugs can be usually be cleaned and installed. White or Gray - Burned or Blistered Insulator Spark Plug Overheating Symptoms: White or gray center electrode insulator that also appears blistered. The increase in electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation. Possible Causes: Plug(s) with wrong heat range. - Over advanced ignition timing. - Detonation - Cooling system malfunction - Check for lean air-fuel mixture - Check the torque value of the plugs to ensure good plug-engine seat contact Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 4215 Spark Plug: Adjustments Setting Spark Plug Gap - Typical Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if extreme care is not used. - Use only a taper gap gauge - Never force the gap gauge through the platinum pads. Only apply enough force until resistance is felt. - Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs - Use an OSHA approved air nozzle when drying gas fouled spark plugs. If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH the platinum pads. Use only a proper gapping tool and check with a taper gap gauge. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 4216 Spark Plug: Service and Repair Fig 1 Spark Plug Boot Heat Shield Orientation WARNING: The ignition cables should not be removed while the engine is hot. This could cause server injury/burns and can cause damage to the ignition cables. CAUTIONS: - Use extreme care when removing and installing the spark plug cables. - The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine (Fig. 1). If it is not installed correctly engine misfire would occur. - Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the shield assembly CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables properly may result in radio interference, ignition cross fire, or ignition short to ground. NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem indicator. SPARK PLUG #3 AND #5 REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head. 3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break the seal with the plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 6. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Install the cable into the retaining bracket. - Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake manifold. 4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6. Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator. SPARK PLUG #1 REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break its seal with the plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This could damage the spark plug Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing and Inspection > Page 4217 insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before installation. 5. Remove spark plug INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark plug cables, make sure the coil or spark plug insulator and terminals are fully seated. - A click sound should be heard or felt when the terminals are properly attached. 3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the accessory drive belt, refer to Cooling System. OTHER PLUGS REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert. INSPECT FOR: Color of Deposits - Excessive Deposits - Electrode wear - Cracked or Damaged Threads Or Insulator - Worn or Bent Electrodes - Damaged Gasket INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading. CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap. 2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be sure connectors are pushed onto plug completely). CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this will allow deposit shifting in the combustion chamber to take place gradually and avoid plug destroying splash fouling shortly after the plug change. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4224 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4235 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4236 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4242 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4243 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4246 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4247 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4248 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4251 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4252 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4253 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4254 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4255 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4256 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4257 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4258 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4259 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4260 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4263 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4264 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4265 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4266 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4267 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4268 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4269 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4270 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4271 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4272 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4273 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4274 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4275 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4276 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4279 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4283 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4284 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4290 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4291 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4292 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4301 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4302 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4303 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4309 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4310 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4315 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4316 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4317 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4323 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4324 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4327 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4328 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4329 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4330 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4331 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4332 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4341 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4346 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4347 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4348 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4354 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4359 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4360 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4361 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4362 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4363 Transmission Speed Sensor: Locations Transmission Control Components Input / Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4366 Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4367 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4373 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4374 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4375 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4376 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4377 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4378 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4379 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4380 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4394 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4395 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4396 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4397 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4406 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4407 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4408 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4409 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall Technical Service Bulletin # 18-05-99 Date: 990226 PCM - Sag/Hesitation/Stumble/Stall NUMBER: 18-05-99 GROUP: Vehicle Performance DATE: Feb. 26, 1999 SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak Detection Pump (LDP) Monitor Test OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control module (PCM) with new software (calibration changes). MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains ^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20° - 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel. 1997/1998 2.4/3.0/3.3/3.8L Powertrains ^ Provides further enhancements to the software originally released in Technical Service Bulletins 18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this subject. 1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California Emission (Sales Code NAE) only included LDP) ^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP monitor. This will allow technicians to verify LDP repairs easily. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the customer has described the above symptoms, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4415 Labor Operation No: 08-19-42-98 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4416 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4421 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4422 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4423 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation PROM - Programmable Read Only Memory: Customer Interest PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 4428 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4434 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4435 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4436 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4437 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4438 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4439 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4440 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4441 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4442 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4443 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4444 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4445 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4446 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4447 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4448 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4449 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4450 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4451 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4452 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall Technical Service Bulletin # 18-05-99 Date: 990226 PCM - Sag/Hesitation/Stumble/Stall NUMBER: 18-05-99 GROUP: Vehicle Performance DATE: Feb. 26, 1999 SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak Detection Pump (LDP) Monitor Test OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control module (PCM) with new software (calibration changes). MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains ^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20° - 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel. 1997/1998 2.4/3.0/3.3/3.8L Powertrains ^ Provides further enhancements to the software originally released in Technical Service Bulletins 18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this subject. 1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California Emission (Sales Code NAE) only included LDP) ^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP monitor. This will allow technicians to verify LDP repairs easily. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the customer has described the above symptoms, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4457 Labor Operation No: 08-19-42-98 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4458 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4463 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4464 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4465 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4470 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4471 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4472 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4473 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 4478 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4484 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4485 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4486 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4487 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4488 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4489 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4490 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4491 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4492 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4493 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4494 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4495 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4496 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4497 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4498 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4499 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4500 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4501 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4502 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall Technical Service Bulletin # 18-05-99 Date: 990226 PCM - Sag/Hesitation/Stumble/Stall NUMBER: 18-05-99 GROUP: Vehicle Performance DATE: Feb. 26, 1999 SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak Detection Pump (LDP) Monitor Test OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control module (PCM) with new software (calibration changes). MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains ^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20° - 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel. 1997/1998 2.4/3.0/3.3/3.8L Powertrains ^ Provides further enhancements to the software originally released in Technical Service Bulletins 18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this subject. 1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California Emission (Sales Code NAE) only included LDP) ^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP monitor. This will allow technicians to verify LDP repairs easily. DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present and the customer has described the above symptoms, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 MDS1 or MDS2 NOTE: THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2 AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4507 Labor Operation No: 08-19-42-98 0.5 Hrs. FAILURE CODE: FM - Flash Module MDS1 Procedure 1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU. 5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then press NEXT MENU. 6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE MDS1 & DRB III(R) on the MDS, then press NEXT MENU. 7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain the current part number of the PCM. 8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s). Press NEXT MENU to begin programming. NOTE: A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). MDS2 Procedures 1. Log onto the MDS2 system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4508 2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information Technical Service Bulletin # 25-02-98 Date: 981023 I/M Testing - OBDII CARB Readiness Monitor Information NO: 25-02-98 GROUP: Emissions DATE: Oct. 23, 1998 SUBJECT: I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information MODELS: 1996 - 1999 (AB) Ram Van/Wagon 1996 - 1999 (AN) Dakota 1996 - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango 1996 - 1999 (FJ) Avenger/Sebring/Talon 1996 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1995 - 1999 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper Roadster/Coupe 1997 - 1999 (TJ) Wrangler 1999 (WJ) Grand Cherokee 1996 - 1999 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE ENGINES. DISCUSSION: Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their tests. It is important to understand that the MIL will not be illuminated because OBD Readiness reads "NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions system occurs. It is possible to have MIL illumination for a detected failure while at the same time having a "NO" for an OBO Readiness monitor. NOTE: MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS BULLETIN. OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for OBD Readiness. Some customers may be directed back to their dealers for assistance when an I/M test station has not allowed an I/M test due to Readiness status. The following procedures will help technicians efficiently run the Readiness tests so an owner can have their I/M test completed. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III(R)) 1 CH7000/7001 J1962Cable 1 CH7OlO J1962 MMC Cable POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4513 TIME ALLOWANCE: Labor Operation No: 25-01-01-91 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure This bulletin involves operating the vehicle under specific parameters to run or complete the OBD monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions application. In addition, the parameters to run each monitor will vary. Preliminary Checks 1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit. 2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year diagnostics, engine, DTC's and related functions, read DTC's. 3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the engine running. NOTE: EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE ATTEMPTING TO RUN THE MONITORS. OBD "CARB" Readiness Check 1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status. 2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO" tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read "YES". NOTE: THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES APPLICABLE FOR THE VEHICLE BEING WORKED ON. The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The pre-test/monitor test screen lists all the preliminary parameters that must be met along with the running parameters for that specific monitor to run. An example of one screen is shown in Figure 1. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4514 NOTE: 1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN. PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE MONITORS RUN WILL BE SIMILAR. The following explains how to interpret each section of the screen: PRE-TEST REQUIREMENTS The pre-test requirements include all the operating parameters that must be met before the actual test can run. The vehicle must be operated until each item within the pre-test section are fulfilled. LOW VALUE/HIGH VALUE/BAR GRAPH The low value/high value provides the minimum and maximum operating conditions for each item (ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when the lowest value required for each item is met. This provides a visual indication that the parameters are being met. The vehicle should be driven until most of each pre-test bar graph is filled. MONITOR REQUIREMENTS Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in the monitor requirements section for the monitors to begin running. As the monitor begins to run, the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician must determine if the pre-test requirements or the monitor requirements have fallen outside the window for the test and the vehicle must be driven accordingly for the test to restart. When the monitor completes its test, the DRB III(R) will beep 3 consecutive times. NOTE: THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR SCREEN FOR THIS MONITOR. MONITOR RUN PROCESS The following will provide the most efficient order along with tips to help run through the monitor tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The only monitors that will require attention are those that read "NO" under the OBD "CARB" Readiness Status screen. Front Wheel Drive 1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or out depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the requirements. 3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test screen for this test to complete. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left in drive for the test to run. If all parameters are met and the test still will not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. 6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded. This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater monitor status. It should have switched to "YES". All other monitors should be completed before running this test. Rear Wheel Drive 1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4515 requirements. 2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen on the DRB III(R) to determine the remaining requirements. 3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet the requirements. 4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the pre-test screen. Automatic transmission vehicles must be left in drive during the stop period. 5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be left in drive for the test to run. If all parameters are met and the test will still not run, place your foot on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells to update. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Improper Cooling Fan Relay Actuation NO: 18-33-97 GROUP: Vehicle Performance DATE: Dec. 31, 1997 SUBJECT: Improper Cooling Fan Relay Actuation MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT PRIOR TO DEC. 1, 1997 (MDH 1201 XX). DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat condition due to cooling fan relay failure. NOTE: ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR HIGHER MUST BE INSTALLED. REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 4520 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay. 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-49-90 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4526 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4527 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4528 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4529 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4530 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4531 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4532 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4533 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4534 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4535 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4536 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4537 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4538 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4539 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4540 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4541 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4542 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4543 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4544 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM Technical Service Bulletin # 771 Date: 980501 Campaign - Radiator Fan Relay and PCM No. 771 May, 1998 To: All Dodge and Chrysler-Plymouth Dealers Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain Control Module Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine ("B", "G","R" or "L" in the 8th VIN Position) Built Through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN Position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position) The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). Dealer Notification & Vehicle List All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. DIAL System Functions 53 and VIP All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification mailing for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The customer name, address and phone number is listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORD771". Parts IMPORTANT: A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand. Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to service about 25% of those vehicles. Each parts package contains the following components: Quantity Description 1 Radiator Fan Relay 2 Screws 1 Label, Authorized Software Update 1 Label Authorized Modifications Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule a service appointment with their dealer. A copy of the owner notification letter is included. Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and notification are identified on the form for owner or dealer reference as needed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4549 Completion Reporting and Reimbursement Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace radiator fan relay and check PCM 08771182 0.3 hours Replace radiator fan relay and reprogram PCM 08771183 0.7 hours Add the cost of the parts package plus applicable dealer allowance to your claim. Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete claim processing instructions. Parts Return Not required. Vehicle Not Available If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to: Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Following the above procedures will expedite the processing of your claim. If you have any questions or need assistance in completing this action, please contact your Zone Service Office. A. Replace Radiator Fan Relay 1. With the ignition key in the OFF position, disconnect the battery. Note: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support. 3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator. 4. Remove the air cleaner housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4550 5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator (Figure 1). 6. Disconnect the radiator fan relay wiring connector. 7. Remove the radiator fan relay. Discard the relay and the attaching screws. 8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4 N.m). CAUTION: Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan relay must be installed using both of the provided screws. 9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position. 10. Install the air cleaner housing. 11. Install the resonator assembly and connect the upper and lower air inlet hoses. 12. Install the resonator to upper radiator support screws. Tighten the screws securely. 13. Connect the negative battery cable. B. Reprogram the PCM 1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and power them up. NOTE: The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed. 2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM. 7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number then press NEXT MENU to begin programming. NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS and then continue with Section D. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4551 C. Install Authorized Software Update Label 1. Type or print (with a ball point pen) the necessary information on the "Authorized Software Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of the label. D. Install the Authorized Modification Label 1. Type or print (with a ball point pen) the following information on the Authorized Modification Label and attach the label near the VECI label (Figure 3). Dealer Service Instructions IMPORTANT DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay and Reprogram PCM ^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through: ^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN position) ^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position) ^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed (flashed). ^ Effective immediately all repairs on involved vehicles are to be performed according to this Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being canceled. Parts Packages: ^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough Radiator Fan Relay Packages to service about 25% of those vehicles. Owner Letter CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE Dear Chrysler Minivan Owner: The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to their dealer for a special service. The problem is... The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the radiator cooling fans. This may cause the engine to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4552 overheat. What Chrysler and your dealer will do... Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will replace the radiator fan relay and reprogram the powertrain control module. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do... ^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required service to your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. We're sorry for any inconvenience, but we believe that this special service will help to ensure your continuing satisfaction with your vehicle. Thanks for your attention to this important matter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4559 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4565 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions Clutch: Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4570 294 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4571 298 Revision to the front pump inspection procedures Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4572 380 Revision to the low reverse reaction plate specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4573 413 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch Clutch: Specifications Low Reverse Clutch Clutch Retainer .................................................................................................................................... .................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > Low Reverse Clutch > Page 4576 Clutch: Specifications 4 Speed Automatic CLUTCH PACK CLEARANCES: L/R (Select Reaction Plate) ....................................................................................................................................... 0.89 - 1.04 mm (0.035 - 0.042 inch) 2/4 (No Selection) ..................................................................................................................................................... 0.76 - 2.64 mm (0.030 - 0.104 inch) Reverse (Select Snap Ring) ....................................................................................................................................... 0.76 - 1.24 mm (0.030 - 0.049 inch) Overdrive (No Selection) .......................................................................................................................................... 0.96 - 2.26 mm (0.038 - 0.089 inch) Underdrive (Select Pressure Plate) ............................................................................................................................ 0.91 - 1.47 mm (0.036 - 0.058 inch) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch Clutch: Description and Operation Input Clutch The input clutch assembly is located directly behind the oil pump housing, and rides on the reaction shaft support journal. The assembly consists of the following: - Input shaft - Input hub - Clutch retainer - Clutch pistons Overdrive hub Underdrive hub Three input clutches (underdrive clutch, overdrive clutch and reverse clutch). When the torque converter turbine turns, the input shaft, hub and clutch retainer also turn Each of the three clutches in the input clutch assembly supply input power to a particular component in the planetary gear train when they are hydraulically applied. They are connected to the planetary gear-train through the overdrive hub assembly, underdrive hub assembly and the front sun gear assembly. When any of these clutches are applied, they turn or drive a component which is an input to the planetary gear-train. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4579 Clutch: Description and Operation Low Reverse Clutch The Low/Reverse (L/R) clutch is used in both low and reverse gears. The L/R clutch is located in the back of the case, directly behind the 2-4 clutch. The L/R clutch actually shares the reaction plate of the 2-4 clutch. It consists of steel plates, clutch discs, belleville return spring, piston and a stamped steel piston retainer which is secured to the back of the case with screws. The L/R clutch surrounds the outside of the front carrier assembly, and locks or grounds the front planetary carrier/rear annulus gear assembly to the case when applied. Similar to the 2-4 clutch, the L/R clutch is a holding element and eliminates the need for bands. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4580 Clutch: Description and Operation Overdrive and Reverse Clutch The Overdrive/Reverse (OD/REV) piston is between the input hub and the clutch retainer. This piston is unique in design for the following reasons: - It operates two separate clutches - It is located on the outside of the clutch retainer that houses the two clutches it operates The overdrive clutch is splined to the overdrive hub assembly, and the overdrive hub is splined to the front carrier assembly. When the overdrive clutch is applied hydraulically, the front carrier assembly is an input to the planetary gear-set in third (direct) and fourth (overdrive) gear ranges. The reverse clutch is splined to the front sun gear assembly. When the reverse clutch is applied hydraulically, it drives the front sun gear which is the input to the planetary gear-set in reverse gear range. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4581 Clutch: Description and Operation Underdrive Clutch The underdrive piston, piston return spring and spring retainer are inside and to the front of the clutch retainer. These parts control the application of the Underdrive (UD) clutch. The underdrive clutch is named for its use in the three forward underdrive gear ranges: first, second and third. The underdrive clutch is splined to the underdrive hub assembly. The underdrive shaft, which is secured to the underdrive hub, is splined to the rear sun gear. When the underdrive clutch is applied hydraulically, the rear sun gear is the input to the planetary gear-set in first, second and third gears. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Input Clutch > Page 4582 Clutch: Description and Operation 2-4 Clutch The 2-4 clutch is used in both second and fourth gears, and is located directly behind the input clutch assembly. The clutch consists of the following: - Stamped steel clutch piston retainer - Aluminum piston - Belleville return spring - Clutch plates - Steel separator plates - Reaction Plate The above parts are held in the case with snap rings. The 2-4 clutch surrounds the outside of the front sun gear assembly and when applied hydraulically, locks or grounds the front sun gear assembly to the case. The 2-4 clutch is a holding element. It is a multidisc clutch that provides more room within the transaxle, and eliminates the need for using a band and servo as are used in other transaxle applications. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Page 4583 Clutch: Testing and Inspection AIR PRESSURE TESTS Inoperative clutches can be located using a series of tests by substituting air pressure for fluid pressure. The clutches may be tested by applying air pressure to their respective passages. Remove the valve body and then install the special tool MB995053 or equivalent. To make air pressure tests, go on as follows: The compressed air supply must be free of all dirt and moisture. Use a pressure of 207 kPa (30 psi). Remove oil pan and valve body. See Valve body removal. Overdrive Clutch Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move forward. The piston should return to its starting position when the air pressure is removed. Reverse Clutch Apply air pressure to the reverse clutch apply passage and watch for the push/pull piston to move rearward. The piston should return to its starting position when the air pressure is removed. 2/4 Clutch Apply air pressure to the feed hole located on the 2/4 clutch retainer. Look in the area where the 2/4 piston contacts the first separator plate and watch carefully for the 2/4 piston to move rearward. The piston should return to its original position after the air pressure is removed. Low/Reverse Clutch Apply air pressure to the low/reverse clutch feed hole (rear of case, between 2 bolt holes). Then, look in the area where the low/reverse piston contacts the first separator plate and watch carefully for the piston to move forward. The piston should return to its original position after the air pressure is removed. Underdrive Clutch Because this clutch piston cannot be seen, its operation is checked by function. Air pressure is applied to low/reverse and the 2/4 clutches. This locks the output shaft. Use a piece of rubber hose wrapped around the input shaft and a pair of clamp-on pliers to turn the input shaft. Next apply air pressure to the underdrive clutch. The input shaft should not rotate with hand torque. Release the air pressure and confirm that the input shaft will rotate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly Clutch: Service and Repair Assembly NOTE: Use petrolatum on all seals to ease assembly of component. 1. Install input shaft to hub. 2. Install input shaft snap ring. Replace lip seals and O-rings. Do not scratch bearing surface. 3. Install return spring and snap ring. Replace O-ring and lip seal of OD/reverse piston. 4. While compressing return spring with Disc 6957, or equivalent and arbor press ram, install snap ring with a screwdriver. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4586 5. Install overdrive/reverse piston by pushing down. Be sure to lubricate reverse piston O-ring and lip seal prior to installation. 6. To install input shaft hub assembly to overdrive/reverse piston, rotate input shaft hub to align splines with overdrive/reverse piston and push down by hand. 7. Install input hub tapered snap ring with snap ring pliers. 8. Install underdrive clutch piston. 9. Install piston return spring. Install Seal Installer 5067 or equivalent. Coat Installer inner surface lightly with petroleum jelly. Place Installer into Input clutch assembly with its large inside diameter facing up. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4587 10. Install underdrive spring retainer. Remove Installer 5067 or equivalent. 11. While compressing spring with Spring Compressor 5059, or equivalent and arbor press ram, install snap ring with snap ring pliers. CAUTION: Compress return spring just enough to install snap ring. 12. Install underdrive clutch pack excluding one clutch disc. 13. Install underdrive clutch reaction plate flat snap ring with a screwdriver. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4588 14. Install last underdrive clutch disc. 15. Install overdrive/underdrive clutch reaction plate with stepped side facing down. 16. Install a new overdrive/underdrive clutches reaction plate tapered snap ring with its tapered side facing up. CAUTION: Do not reuse tapered snap ring. Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around. CAUTION: Do not scratch reaction plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4589 17. Set up dial indicator set MB995030 or equivalent and steel bar as shown for checking clutch clearance. Compress clutch pack with finger to zero dial indicator. 18. Use hook tool to raise top clutch disc. Read dial indicator. Underdrive clutch pack clearance must be 0.91 to 1.47 mm (0.0358 to 0.0579 inch). Select the proper reaction plate to achieve specifications. 19. Install overdrive clutch pack starting with a clutch disc. 20. Install overdrive reaction plate waved snap ring into the wide groove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4590 21. Install overdrive/reverse pressure plate with stepped side down. 22. While pressure down overdrive/reverse pressure plate with Spring Compressor 5059, or equivalent and arbor press ram, install flat snap ring. CAUTION: Press down just enough to expose snap ring groove. 23. Check overdrive clutch pack clearance. The Overdrive (OD) clutch pack clearance is 1.07 to 2.44 mm (0.421 to 0.0961 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance. 24. Install reverse clutch pack. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4591 25. Install reverse clutch reaction plate with flat side down. 26. Install reverse clutch snap ring with a screwdriver. 27. Raise reverse clutch reaction plate by prying up at two locations with screwdrivers to seat snap ring. 28. Check reverse clutch pack clearance by lifting reverse clutch reaction plate using a hook tool. The reverse clutch pack clearance is 0.76 to 1.24 mm (0.0299 to 0.0488 inch). Select the proper reverse clutch snap ring to achieve specifications. Thickness: 1.56 mm (0.0614 inch) 1.80 mm (0.0709 inch) 2.05 mm (0.0807 inch) 2.30 mm (0.0906 inch) All clutch clearances in the input clutch retainer have now been checked and approved. To complete the assembly of the input clutch retainer, the reverse clutch and the overdrive clutch must be removed from the retainer. CAUTION: Do not intermix clutch parts. Keep in the same order. 29. After removing reverse and overdrive clutches, install No. 2 needle bearing with 3 small tabs facing up. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4592 30. Install underdrive shaft assembly. 31. Install No. 3 thrust washer. 32. Stick No. 3 thrust plate onto overdrive shaft assembly with dabs of petrolatum. 33. Install overdrive shaft assembly. Now that both shaft assemblies and thrust washers are properly installed, reinstall overdrive clutch and reverse clutch as shown in steps 19 - 26. Rechecking these clutch clearances is not necessary, as they were set and approved previously. 34. Reassembly of input clutch assembly is now complete. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4593 Clutch: Service and Repair Disassembly NOTE: Place input clutches assembly on wood blocks or equivalent, as shown to facilitate disassembly and reassembly. 1. Tap down reverse clutch reaction plate to remove (or install) snap ring. 2. Using a screwdriver, remove the reverse clutch snap ring. 3. Loosen reverse clutch reaction plate by prying at two locations with screwdrivers as shown. 4. Remove reverse clutch reaction plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4594 5. Remove clutch plates and discs. Tie plates and discs together so they go back in the same location. 6. Remove overdrive/reverse pressure plate snap ring. 7. Remove overdrive/reverse pressure plate. 8. Remove overdrive/reverse clutch waved snap ring with a screwdriver. 9. Remove overdrive shaft assembly and overdrive clutch pack. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4595 10. Disassemble overdrive clutch pack. Tie plates and discs together so they go back in the same location. 11. Remove No. 3 and No. 4 thrust plates from overdrive shaft assembly. 12. Remove underdrive shaft assembly. 13. Remove No. 2 needle bearing. 14. Remove overdrive/underdrive clutches reaction plate tapered snap ring. Do not scratch reaction plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4596 15. Remove overdrive/underdrive clutch reaction plate. 16. Remove one underdrive clutch disc. 17. Remove underdrive clutch reaction plate flat snap ring. 18. Remove clutch plates and discs. Tie together so plates and discs go back into the same location. 19. Remove snap ring with snap ring pliers while compressing return spring with Spring Compressor 5059, or equivalent and arbor press ram. CAUTION: Compress return spring just enough to remove snap ring. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4597 20. Remove underdrive spring retainer and spring. 21. Remove underdrive clutch piston. 22. Remove input hub snap ring with snap ring pliers. 23. Tap on input shaft and hub assembly with a plastic hammer. 24. Remove input shaft and hub assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Assembly > Page 4598 25. Remove overdrive/reverse piston. 26. Remove snap ring with a screwdriver while compressing return spring with Disc 6057 and arbor press ram or equivalents. 27. Remove snap ring and return spring. 28. Remove input shaft snap ring. 29. Remove input shaft from hub. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4607 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4608 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4614 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4615 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4618 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4619 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4620 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4623 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4624 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4625 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4626 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4627 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4628 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4629 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4630 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4631 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4632 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4635 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4636 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4637 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4638 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4639 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4640 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4641 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4642 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4643 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4644 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4645 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4646 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4647 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4648 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4651 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations Data Link Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T > Component Information > Locations > Page 4655 Data Link Connector (16 - Way) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Carrier Assembly, A/T > Carrier Bearings, A/T > Component Information > Specifications Carrier Bearings: Specifications Retainer Bolts ...................................................................................................................................... ..................................................... 28 Nm (21 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Case, A/T > Component Information > Specifications Differential Case: Specifications Mounting Bolts ..................................................................................................................................... ............................................... 19 Nm (165 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Ring Gear, A/T > Component Information > Specifications Ring Gear: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 95 Nm (70 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Mounting Bolts ..................................................................................................................................... .................................................... 28 Nm (21 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4674 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4675 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid 31TH .................................................................................................................................................... ............................................................. 8.0L (8.5 Qt) 41TE ................................................................. ................................................................................................................................................ 8.6L (9.1 Qt) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4678 Fluid - A/T: Fluid Type Specifications See TSB 21-010-06 4/14/2006 Transmission Fluid Type Type ......................................................................................................................................................... Mopar (R) ATF Plus 4 Type 9602, Or Equivalent Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check Fluid - A/T: Service and Repair Fluid Level & Condition Check Fluid Level The transmission and differential sump have a common oil sump with a opening between the two. The torque converter fills in both the "P" Park and "N" Neutral positions. Place the selector lever in "P" Park to check fluid level. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. This will assure complete oil level stabilization between differential and transmission. The fluid should be at normal operating temperature (approximately 82 C. or 180 F). The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator. Fluid Condition Along with fluid level, it is important to check the condition of the fluid. - When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle overhaul is needed. Be sure to examine the fluid on the dipstick closely. - If there is any doubt about its condition, drain out a sample for a double check. Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Low Fluid Level Symptoms Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be low and build up slowly. Improper Filling Level Symptoms Improper filling can also raise the fluid level too high. - When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a leak. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 4681 Fluid - A/T: Service and Repair Fluid and Filter Change Fluid and Filter Change When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level & Condition Check > Page 4682 Fluid - A/T: Service and Repair Fluid Drain and Refill Procedure 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to 19 Nm (165 in-lbs). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick. CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil (100F). Upper holes for hot oil (180F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill Fluid Filter - A/T: Service and Repair Fluid Drain and Refill 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark. CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil (100°F). Upper holes for hot oil (180°F). 8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Fluid Drain and Refill > Page 4687 Fluid Filter - A/T: Service and Repair Fluid & Filter Change When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a clean, dry cloth. If the transaxle is disassembled for any reason, the fluid and filter should be changed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T Oil Cooler Line Hose Clamp - Revised Fluid Line/Hose: Technical Service Bulletins A/T Oil Cooler Line Hose Clamp - Revised NUMBER: 07-006-01 GROUP: Cooling DATE: Nov. 11, 2001 SUBJECT: Transmission Oil Cooler Line Hose Clamp Service OVERVIEW: This bulletin provides revised transmission oil cooler hose clamp information. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) DISCUSSION: A revised transmission oil cooler hose clamp is now available and should be used any time it is necessary to separate oil cooler hose connections. Tighten the clamp(s) to 3.2 Nm (28 in. lbs.). Transmission oil cooler hoses should be replaced only it they are damaged. NOTE: WEATHERED SURFACE APPEARANCE ON TRANSMISSION OIL COOLER HOSES IS A NORMAL CONDITION AND WILL NOT IMPAIR THEIR ABILITY TO SEAL. PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 4692 Fluid Line/Hose: Specifications Fittings ................................................................................................................................................. ............................................... 12 Nm (105 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 4693 Fluid Line/Hose: Service and Repair FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. COOLER FLUSH USING TOOL 6906A 1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar (R) ATF Plus 4 Type 7176 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. 14. Check for debris on cooler and remove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications TORQUE SPECIFICATIONS Bolt, Oil Pan-to-Case ........................................................................................................................... ..................................................... 19 Nm (14 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4705 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4706 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4707 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4713 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4714 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4715 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4720 294 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4721 298 Revision to the front pump inspection procedures Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4722 380 Revision to the low reverse reaction plate specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4723 413 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions NUMBER: 26-11-97H GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revisions to Test 53 - Repairing speed ratio in third gear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4729 294 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4730 298 Revision to the front pump inspection procedures Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4731 380 Revision to the low reverse reaction plate specifications Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97 > A/T - 41TE/41TA Service Manual Revisions > Page 4732 413 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4733 Fluid Pump: Specifications CLEARANCES: Outer Gear To Pocket ....................................................................................................................................... 0.045 - 0.141 mm (0.0018 - 0.0056 inch) Outer Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) Inner Gear Side Clearance ................................................................................................................................ 0.020 - 0.046 mm (0.0008 - 0.0018 inch) TIGHTENING TORQUE: Mounting Bolts ..................................................................................................................................... ................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4734 Fluid Pump: Description and Operation The oil pump is located in the pump housing inside of the bell housing of the transaxle case, and is similar to oil pumps used in other Chrysler applications. The inner gear is driven by the torque converter impeller hub. Torque is supplied to the impeller hub by the engine crankshaft through the flex plate and converter housing. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. Fluid is pulled through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces fluid into the pump outlet. The pressurized oil from the outlet operates the torque converter, clutches and the lubrication system. The pump is held in the housing by the reaction shaft support Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Page 4735 Fluid Pump: Testing and Inspection After the new or repaired transmission has been installed, fill to the proper level with Mopar (R) ATF Plus 4 (Type 7176), or equivalent automatic transmission fluid. The volume should be checked using the following procedure: 1. Disconnect the From cooler line at the transmission and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, disconnect the To Cooler line at the transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be within acceptable limits, replace the cooler. Then fill.transmission to the paper level, using. Mopar (R) ATF Plus 4 (Type 7176), or equivalent automatic transmission fluid. 6. If fluid flow is still found-to be inadequate, check the line pressure using the Transaxle Hydraulic Pressure Test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information Planetary Gears: Description and Operation General Information The entire planetary gear-train is located behind the input clutch assembly and is inside the 2-4 and L/R clutch assemblies. The planetary gear-train consists of two sun gears, two planetary carriers, two annulus (ring) gears and one output shaft which is part of the rear carrier. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 4740 Planetary Gears: Description and Operation Front Carrier Assembly The front planetary carrier and gear annulus (ring) gear are splined together as one unit. When the overdrive clutch is applied, it drives the front carrier assembly by the overdrive hub. When the low/reverse clutch is applied, it holds or prevents the front carrier assembly from rotating. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > General Information > Page 4741 Planetary Gears: Description and Operation Rear Carrier Assembly The rear planetary carrier, front annulus (ring) gear and output shaft are all one assembly. The rear carrier assembly provides all output power for the transaxle assembly. In other words, all output from the transaxle must go through the rear carrier. The lugs around the outside of the assembly have two purposes: - To engage the parking pawl when the driver selects park - To generate an output speed signal used by the TCM There are no clutches splined or connected to this unit in any way. The rear carrier assembly is supported to the case by two tapered roller bearings, which must be set up with specific preload and measured by turning torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4751 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4752 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4758 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4759 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4762 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4763 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4764 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4767 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4768 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4769 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4770 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4771 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4772 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4773 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4774 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4775 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4776 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4779 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 - Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4780 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4781 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4782 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4783 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4784 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4785 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4786 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4787 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4788 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4789 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4790 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4791 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 4792 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 4795 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4799 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4800 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4809 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4810 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4811 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 4817 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4822 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4823 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4824 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation Technical Service Bulletin # 21-05-99A Date: 990903 A/T Pan Gasket - Reusable Design/Installation NUMBER: 21-05-99 Rev. A GROUP: Transmission DATE: Sep. 03, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL COVERAGE. SUBJECT: Reusable Automatic Transmission Oil Pan Gasket OVERVIEW: This bulletin announces availability and installation of a reusable automatic transmission oil pan gasket. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon **1989** - 1993 (AG) Daytona **1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible **1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (European Market) 1995 - **2000** (JA) Cirrus/Stratus/Breeze 1996 - **2000** (JX) Sebring Convertible **1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M** 1996 - **2000** (NS) Town & Country/Caravan/Voyager **1995 - 2000 (PL) Neon** **1997 - 2000 (PR) Prowler** DISCUSSION: A reusable silicone gasket has been developed to replace the RTV method of sealing the automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is recommended that this gasket be used in all applications. NOTE: THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES. PARTS REQUIRED: **1 05011113AA Gasket, Transmission Oil Pan, 31TH** **1 05011114AA Gasket, Transmission Oil Pan, 42LE** 1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE POLICY: INFORMATION ONLY POLICY: Information Only Installation Procedure 1. With oil pan removed from transmission case for routine service or transmission repair proceed to step # 2. 2. Clean any residue from oil pan and magnet. 3. Replace O-ring and filter on bottom of valve body. 4. Using a plastic or wooden scraper, remove old RTV from transmission case rails. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 4830 CAUTION: ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING THESE COMPONENTS. 5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails. 6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission case. Tighten oil pan bolts to 19 Nm (165 in lbs.). 7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles. CAUTION: DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4831 Seals and Gaskets: By Symptom Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4832 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4833 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4834 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4835 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4836 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4837 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4838 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Page 4839 Seals and Gaskets: Service and Repair Remove Oil Pump Seal Install Oil Pump Seal Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4844 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4845 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4846 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4855 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4856 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4857 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4863 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4864 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4869 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4870 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4871 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4877 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4878 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4881 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4882 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4883 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4884 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4885 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4886 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4895 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4900 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4901 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4902 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4908 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4913 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4914 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4915 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4916 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4917 Transmission Speed Sensor: Locations Transmission Control Components Input / Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 4920 Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4921 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4948 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4949 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 4950 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4951 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Adjustments Shift Interlock: Adjustments If ignition switch cannot be turned to the LOCK position, with shifter in PARK, an adjustment of the Interlock System may be required. To adjust Shifter/Ignition Interlock System. follow procedure listed below. 1. Disconnect and isolate, the battery negative (-) cable from the vehicle battery. 2. Remove console assembly. 3. Remove the gearshift knob set screw and knob. 4. Remove the screws retaining the gearshift indicator bezel and remove bezel and indicator lamp. 5. Reinstall the gearshift knob. 6. Place shifter in PARK. 7. Turn ignition switch to the LOCK or ACCESSORY position. If cable has lost its adjustment, manually position cable to get key into LOCK or ACCESSORY position. Grasp slug on interlock cable with needle-nose pliers and pull back on cable. This will allow the ignition switch to be turned to the LOCK or ACCESSORY position. 8. Check that the interlock cable slug is completely seated into the shifter interlock lever. 9. Check that the ignition switch is still in the LOCK or ACCESSORY position. 10. Pry up the adjuster lock on the shifter/ignition interlock cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Component Information > Adjustments > Page 4955 11. The spring on the interlock cable should automatically compensate for the slack in the adjuster. 12. Then snap down the interlock adjuster lock onto cable. 13. After adjusting the interlock system, perform the inter lock system operation check. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 4959 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair Selector Shaft: Service and Repair REMOVAL 1. Remove shift cable from lever. 2. Loosen the lever mounting bolt. Do not remove bolt (not necessary). 3. Pull up on lever and remove. INSTALLATION For installation, reverse removal procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Lift and rotate the gearshift hand lever into the park (P) gate position and remove the ignition key. This confirms the shift lever is in the gated park (P) position. After confirming the park gate position, turn the ignition switch . If the starter will operate, the park gate position is correct. Move the shift lever into the neutral (N) position. If the starter will operate in this position, the linkage is properly adjusted. If the starter fails to operate in either position, linkage adjustment is required. 1. Park the vehicle on level ground and set the parking brake. 2. Place the gearshift lever in park (P) gate position and remove key. 3. Loosen the cable adjustment screw at the transaxle operating lever. 4. Pull the transaxle operating lever fully forward to the park detent position. 5. Release the park brake, then rock the vehicle to assure it is in park lock. Reset the park brake. 6. Tighten the cable adjustment screw to 8 Nm (70 inch lbs.). Gearshift cable should now be properly adjusted. 7. Check adjustment by using the preceding procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4967 Shift Cable: Service and Repair REMOVAL 1. Remove cable eyelet attachment from transaxle operating lever pin. 2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket and push through hole to remove. 3. At the steering column attachment, remove the cable eyelet attachment from the shift lever pin. 4. Using pliers, squeeze ears of cable attachment at mounting bracket then push through hole to remove. 5. Unseat the dash grommet and remove the cable from the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4968 6. Remove the under instrument panel silencer. INSTALLATION 1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged. Verify cable does not interfere with brake pedal actuation. 2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed through the slot in the silencer. CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference. 5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7. Complete adjustment using the gearshift cable adjustment procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly Sun Gear: Description and Operation Front Sun Gear Assembly The front sun gear assembly rides in the center of the front carrier, and is welded to the center of two hubs that are arranged back to back. Each of the hubs are splined to a clutch. The front-most hub is splined to the reverse clutch which turns the front sun gear when it is applied. The rearward hub is splined to the 2-4 clutch which prevents the front sun gear from turning when it is applied. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Description and Operation > Front Sun Gear Assembly > Page 4973 Sun Gear: Description and Operation Rear Sun Gear The rear sun gear is located in the center of the rear carrier assembly. There are two thrust bearings located on either side of the sun gear. When the underdrive clutch is applied, it drives the rear sun gear through the underdrive hub and shaft. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications Torque Converter: Specifications Diameter .............................................................................................................................................. ................................................ 241 mm (9.48 inches) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > Page 4977 Torque Converter: Description and Operation The torque converter is similar in function and design to other Chrysler torque converters. The torque converter clutch engages or disengages the turbine assembly to the impeller housing. The application of the converter clutch is controlled electronically by the solenoid assembly and valve body. The torque converter transmits torque from the engine crankshaft to the input shaft of the transaxle. The torque converter clutch may engage (under the right conditions) in either 2nd, 3rd or 4th gears. The torque converter clutch engagement is normally very smooth and may even be undetectable by the driver. There are two types of torque converter engagement: partial and full engagement. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4981 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4982 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications Transmission Cooler: Specifications Hose Clamps-All Engines .................................................................................................................... ...................................................... 2 Nm (18 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4986 Transmission Cooler: Description and Operation Oil cooler is internal oil to coolant type, mounted in the radiator left tank. Rubber oil lines feed the oil cooler and the automatic transmission. Use only approved transmission oil cooler hose. Since these are molded to fit space available, molded hoses are recommended. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4987 Transmission Cooler: Service and Repair FLUSHING COOLERS AND TUBES When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler bypass valve in the transaxle must be replaced also. The torque converter must also be replaced with an exchange unit. This will insure that metal particles or sludged oil are not later transferred back into the reconditioned (or replaced) transaxle. The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher. WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear standard industrial rubber gloves. - Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where the flusher will be used. - Keep the area well ventilated. - Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin with soap and water. Seek medical attention. COOLER FLUSH USING TOOL 6906A 1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh flushing solution. Flushing solvents are petroleum based solutions generally used to clean automatic transmission components. DO NOT use solvents containing acids, water, gasoline, or any other corrosive liquids. 2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4. Disconnect the cooler lines at the transmission. NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. 5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s) and lines. Monitor pressure readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is intermittent or exceeds these pressures, replace cooler. 8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect CLEAR return line at cover plate, and place it in a drain pan. 10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump OFF. 11. Place CLEAR suction line into a one quart container of Mopar (R) ATF Plus 4 Type 7176 automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one quart container and lines. This purges any residual cleaning solvent from the transmission cooler and lines. Turn pump OFF. 13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove flushing adapters from cooler lines. 14. Check for debris on cooler and remove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4991 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4992 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4993 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5002 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5003 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5004 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5010 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5011 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5016 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5017 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5018 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5024 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5025 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5028 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5029 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5030 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5031 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5032 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5033 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations 41 TE/AE Transaxle Pressure And Cooler Ports Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5045 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5050 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5051 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5052 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5058 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5063 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5064 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5065 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5066 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5067 Transmission Speed Sensor: Locations Transmission Control Components Input / Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5070 Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5071 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5098 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5099 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5100 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 5101 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5110 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5111 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5112 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5118 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5119 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5120 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5121 Valve Body: Specifications Valve Body To Case Bolts ................................................................................................................... ............................................... 12 Nm (105 inch lbs.) Valve Body Bolts .............................................. ...................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5122 A604 (41TE) 4 Speed Transaxle Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5123 A604 (41TE) 4 Speed Transaxle Solenoid Pack Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5126 Valve Body: Description and Operation Manual Valve The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5127 Valve Body: Description and Operation Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5128 Valve Body: Description and Operation Solenoid Switch Valve The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when needed. The valve must return to the right before a downshift to 1st gear can occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5129 Valve Body: Description and Operation General Information The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a positive displacement, gear and crescent type pump. It is driven by the engine through the torque converter hub. The valve body has two major functions: - Control line pressure and TCC pressure - Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of the manual and switch valves Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator valve. The valve body uses five valves along with four solenoids in the solenoid assembly to provide control of the transaxle through all of its gear ranges. They perform all functions needed to operate the transaxle for each of its gear ranges. Manual Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5130 The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the middle position in both Park and Neutral. The valve moves to the right position when Reverse is selected. Regulator Valve The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits, pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure. Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring tension working against oil pressure to keep or maintain the oil at specific pressures. Regulated.pressure varies depending on the gear range the transaxle is operating in. A system of sleeves and ports allows the regulator valve to work at one of three different predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the intake side of the oil pump. Solenoid Switch Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5131 The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when needed. The valve must return to the right before a downshift to 1st gear can occur. Torque Converter Clutch Control Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5132 The Torque Converter Clutch (TCC) control valve controls the back (ON) side of the torque converter clutch. When the TCM energizes the LR/CC solenoid to engage the converter clutch piston, the TCC control valve and torque converter control valves move to the left. The oil on the front (OFF) side of the converter clutch piston is vented to the sump. Line pressure enters the TCC control valve through the manual valve, and then passes through the TCC control valve and the torque converter control valve to the back (ON) side of the converter clutch piston. Line pressure forces the piston forward, which engages the torque converter clutch. This action effectively connects the torque converter turbine with the impeller. Line pressure also flows from the regulator valve, through the torque converter control valve, to the cooler and cooler bypass, for improved fluid and transaxle cooling. Torque Converter Control Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > General Information > Page 5133 The torque converter control valves main responsibility is to control. hydraulic pressure applied to the front (OFF) side of the converter clutch. Line pressure from the regulator valve is fed to the torque converter control valve, where it passes through the valve. The torque converter control valve reduces, or regulates, the pressure slightly. The torque converter control valve pressure is then directed to the converter clutch control valve and to the front side of the converter clutch piston. The pressure that is being fed to the front of the piston pushes the piston back. This disengages the converter clutch. The oil then passes around the outside of the piston, flowing out of the torque converter and back to the torque converter control valve. From the torque converter control valve, the oil flows to the transaxle oil cooler and cooler bypass valve. It returns to the transaxle as lube oil pressure. Beginning in 1996, the torque converter control valve was modified to delete the function of regulating the flow to the torque converter when the converter clutch is not applied. The valve switches the direction of fluid flow when the converter clutch is applied and vents the release side of the torque converter clutch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation Removal Oil Pan Bolts Oil Pan Oil Filter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5136 Valve Body Attaching Bolts NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Push Park Rollers From Guide Bracket Remove Valve Body Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5137 Valve Body Removed Installation To install valve body, reverse removal procedure. CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise. Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the installation position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5138 Valve Body: Service and Repair Solenoid Assembly Replacement REMOVAL Input Speed Sensor Removed Remove Sound Cover Remove Attaching Screws Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5139 Remove Solenoid Assembly INSTALLATION To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5140 Valve Body: Service and Repair 41TE 4-Speed Transmission Range Sensor Screw Transmission Range Sensor Removed Manual Shaft And Rooster Comb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5141 2-4 Accumulator Plate TRS, Manual Shaft, And 2-4 Accumulator Valve Body Screws Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5142 Valve Body And Transfer Plate Transfer Plate And Separator Plate Ball Check Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 5143 Springs And Valves Location Remove Or Install Dual Retainer Plate TC Limit Valve And Low/Reverse Switch Valve Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Capacity ............................................................................................................................................... ......................................................... 1.9L (4.0 Pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5149 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Grade ................................................................................................................................................... ................................................................... API GL-5 Viscosity .............................................................................................................................................. ..................................................................... 85W-90 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 5150 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications TIGHTENING SPECIFICATIONS Caliper To Knuckle Bolts ..................................................................................................................... ................................................ 31 Nm (23 ft. lbs.) Driveshaft Nut ....................................................... ........................................................................................................................... 244 Nm (180 ft. lbs.) Front Wheel Lug Nuts .......................................................................................................................... ............................................ 135 Nm (100 ft. lbs.) Knuckle To Ball Stud Nut ...................................... .............................................................................................................................. 95 Nm (70 ft. lbs.) Tie Rod End To Knuckle ...................................................................................................................... ................................................ 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5156 Axle Shaft: Service Precautions CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This, design though, eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. The inner joint sealing boot will be serviced, as on past applications, as a separate component of the driveshaft assembly. CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends, can cut boots or damage C/V joints. During removal and installation procedures, always support both ends of the driveshaft to prevent damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5157 Axle Shaft: Application and ID Driveshaft Identification Driveshafts and driveshaft inner and outer boots can be identified as shown. Driveshaft boot location on the driveshaft assemblies, is determined by the number of convolutes used on the driveshaft boot. Refer to image for the correct location of the sealing boots. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5158 Axle Shaft: Description and Operation GENERAL INFORMATION Vehicles equipped with either an automatic or manual transmission uses an unequal length driveshaft system. Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side. The right side of the vehicle uses a longer solid interconnecting shaft. Driveshafts used on both the right and left sides of the vehicle use a tuned rubber damper weight. The damper weight on the right side is a single clamp style damper. The damper weight on the left side is a double clamp style damper. When replacing a driveshaft, be sure the replacement driveshaft has the same damper weight as the original. Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa joint. Both tripod joints and Rzeppa joints are true Constant Velocity (C/V) joint assemblies. The inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel of the front suspension. On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation. The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained by a hub nut using a nut lock and cotter pin, hub nut retention system. NOTE: This vehicle does not use a rubber lip bearing seal as on past front wheel drive cars, to prevent contamination of the front wheel bearing. On these vehicles, the face of the outer C/V joint has a metal bearing shield which is pressed onto the end of the outer C/V joint housing. This design deters direct water splash on bearing seal while allowing any water that gets in, to run out the bottom of the bearing shield. It is important though to thoroughly clean the outer C/V joint and the wheel bearing area in the steering knuckle before it is assembled after servicing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 5159 Axle Shaft: Testing and Inspection ON-VEHICLE INSPECTION 1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of inner or outer joint seal boot or seal boot clamp damage. 2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered normal and should not require replacement of the seal boot. NOISE AND/OR VIBRATION IN TURNS A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1. Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss and/or contamination of the joint grease, resulting in inadequate lubrication of the joint. 2. Noise may also be caused by another component of the vehicle coming in contact with the driveshafts. CLUNKING NOISE DURING ACCELERATION This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the driveshaft assembly. 3. A damaged or worn driveshaft C/V joint. SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. Refer to Steering and Suspension for alignment checking and setting procedures and specifications. VIBRATION AT HIGHWAY SPEEDS This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the wheel(s). 2. Out of balance front tires or wheels. Refer to Steering and Suspension for the required balancing procedure. 3. Improper tire and/or wheel runout. Refer to Steering and Suspension for the required runout checking procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation Axle Shaft: Service and Repair Removal & Installation REMOVAL CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.). This will ensure that the hub bearing cannot loosen. Cotter Pin, Nut Lock And Spring Washer 1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle. Loosening Front Hub Retaining Nut 2. Loosen (but do not remove) stub axle to hub/ bearing retaining nut. Loosen hub nut while vehicle is on the floor with the brakes applied. The front hub and driveshaft are splined together and retained by the hub nut. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove front tire and wheel assembly from the hub. Caliper Guide Pin Attaching Bolts Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5162 5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts. Removing Disk Brake Caliper 6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting bottom of caliper away from steering knuckle, and then removing top of caliper out from under steering knuckle. Correctly Supported Brake Caliper 7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the brake Hex hose. 8. Remove braking disc from front hub. Removing Tie Rod End Attaching Nut 9. Remove nut attaching outer tie rod end to steering knuckle. Remove nut from tie rod end by holding tie rod end stud with a 11/32 socket and loosen and remove nut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5163 Tie Rod End Removal From Steering Knuckle 10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool MB-991113. Wheel Speed Sensor Cable Routing Bracket 11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the steering knuckle. Lower Ball Joint To Steering Knuckle Attachment 12. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle. CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 13. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5164 Separating Ball Joint Stud From Steering Knuckle 13. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel well as possible. Using a hammer strike steering knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint. Driveshaft must be supported. Separating Steering Knuckle From Outer C/V Joint 14. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly. CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be used to ensure no damage occurs to oil seal in transaxle case. Disengaging Inner Tripod Joint From Transaxle 15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case. Pry against inner tripod joint, until Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5165 tripod joint retaining snap ring is disengaged from transaxle side gear. Tripod Joint Removal From Transaxle 16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.). This will ensure that the hub bearing cannot loosen. INSTALLATION 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand. 3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle. Outer C/V Joint Inspection 5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5166 Steering Knuckle Installation On Outer C/V Joint 6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball joint stud. Lower Ball Joint To Steering Knuckle Attachment 7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft. lbs.). Wheel Speed Sensor Cable Routing Bracket 8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and securely tighten bolt. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5167 Installing Tie Rod End Nut Torquing Tie Rod End Nut 9. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten the nut to 61 Nm (45 ft. lbs.). 10. Install braking disc back on hub and bearing assembly. Disk Brake Caliper Assembly Installation 11. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of caliper under top abutment on steering knuckle. Then installing bottom of caliper against bottom abutment of steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5168 Disk Brake Caliper Bolts 12. Install caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly bolts to 31 Nm (23 ft. lbs.). Install Washer And Hub Nut 13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto threads of stub axle and tighten nut. Torquing Front Hub Nut 14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 Nm (180 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5169 Spring Washer, Nut Lock And Cotter Pin Installation 15. Install the spring washer, hub nut lock, and new cotter pin on end of stub axle. Wrap cotter pin prongs tightly around the hub nut lock. Wheel Lug Torquing Sequence 16. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct sequence. Tighten lug nuts to 135 Nm (100 ft. lbs.). 17. Lower vehicle. 18. Check for correct fluid level in transaxle assembly. Transaxle for the correct fluid level checking procedure for the type of transaxle being checked. 19. Set front toe on vehicle to required specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5170 Axle Shaft: Service and Repair Outer C/V Joint Bearing Shield Service The front hub/bearing shield on the outer C/V joint is a serviceable component of the outer C/V. If it is damaged in use on a vehicle or during servicing of a driveshaft it can be replaced using the following procedure. To remove the bearing shield from the outer C/V joint, the driveshaft assemblies must be removed from the vehicle. See Servicing Driveshaft, for the required driveshaft removal and replacement procedure. REMOVAL 1. Clamp driveshaft in a vise by the interconnecting shaft. Removing Bearing Shield From Outer C/V Joint 2. Using a drift, tap around the entire edge of the bearing shield until it is removed from the outer C/V Joint. INSTALLATION 1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint. Special Tools For Installing Bearing Shield 2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1 on face of bearing shield. CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference with steering knuckle will occur when driveshaft is installed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5171 Correctly Installed Bearing Shield 3. Using a hammer, drive the bearing shield on the outer C/V joint until it is flush against the front of the outer C/V joint. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal & Installation > Page 5172 Axle Shaft: Service and Repair Overhaul CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement of the driveshaft seal boots on the inner tripod joints. If any failure of internal driveshaft components is diagnosed during a vehicle road test or disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly. CAUTION: Lubricant requirements and quantities are different for inner joints than for outer joints. Use only the recommended lubricants in the required quantities when servicing driveshaft assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5173 Axle Shaft: Tools and Equipment Bearing Shield Installer C-4698 Tie Rod Remover MB-990635 Boot Clamp Installer C-4975A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > CV Boot - Grease Seepage Explanation Constant Velocity Joint Boot: Technical Service Bulletins CV Boot - Grease Seepage Explanation NO: 03-06-98 GROUP: Differential & Drive Line DATE: Oct. 2, 1998 SUBJECT: CV Boot Grease Seepage MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: The right side half shaft inner CV joint boot on subject vehicles is made of a special high temperature resistant material that can show heavy grease seepage - enough to form droplets on the boot convolutes. Although the seepage is unsightly and will stop eventually, it does not affect function or durability. No replacement of the half shaft or boot is necessary for this condition. The boot should be wiped clean as necessary. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Seal Boot REMOVAL To remove sealing boots from driveshafts, the driveshaft assemblies must be removed from the vehicle. See Driveshaft for the required driveshaft removal and replacement procedure. The inner tripod joints use no internal retention in the tripod housing to keep the spider assembly in the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod housing from transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. See Servicing Driveshaft for the required driveshaft; removal procedure. 2. Remove large boot clamp which retains inner tripod joint sealing boot to tripod joint housing and discard. Remove small clamp which retains inner tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider trunions to prevent the bearings from failing away. Spider Assembly Removal From Tripod Joint Housing 3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft. Spider Assembly Retaining Snap Ring Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5180 Spider Assembly Removal From Interconnecting Shaft 4. Remove snap ring which retains spider assembly to interconnecting shaft. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. 5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the driveshaft assembly will require replacement. Component parts of these driveshaft; assemblies are not serviceable. INSTALLATION NOTE: The inner tripod joint sealing boots are made from two different types of material. High temperature applications use silicone rubber where as standard temperature applications use hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot which was removed. Sealing Boot Installation On Interconnecting Shaft 1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the replacement inner tripod joint sealing boot onto the interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so the raised bead on the inside of the seal boot is in groove on interconnecting shaft. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5181 Spider Assembly Installation On Interconnecting Shaft Installing Spider Assembly On Interconnecting Shaft 2. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Spider Assembly Retaining Snap Ring Installed 3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of interconnecting shaft. Be sure the snap ring is fully seated into groove on interconnecting shaft. 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5182 Installing Tripod Housing On Spider Assembly 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly on sealing boot. Crimping Tool Installed On Sealing Boot Clamp Sealing Boot Retaining Clamp Installed 7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the following procedure. Place crimping tool C-4975-A over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped correctly, equalize pressure in seal and shape it by hand. 8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. CAUTION: The following positioning procedure determines the correct air pressure inside the inner tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability can be adversely affected. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5183 CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. Trim Sticker Inserted For Venting Tripod Joint 9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly. When inserting trim stick between tripod housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the hard plastic sealing boot and soft rubber insert. 10. With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing. This procedure will equalize the air pressure in the tripod joint, preventing premature sealing boot failure. 11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A. Crimping Tool Installed On Sealing Boot Clamp - Place crimping tool C-4975-A over bridge of clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5184 Sealing Boot Retaining Clamp Installed - Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face. LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an equivalent. Clamping Tool Installed On Sealing Boot Clamp - Place prongs of clamp locking tool in the holes of the clamp. Sealing Boot Clamp Correctly Installed - Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp. 13. Install the driveshaft back on the vehicle. See Servicing Driveshaft, for the required driveshaft installation procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5185 Constant Velocity Joint Boot: Service and Repair Outer C/V Joint Sealing Boot Service CAUTION: The outer C/V joint used on this vehicle is not a serviceable joint. CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the interconnecting shaft. These driveshafts; incorporate a slight twist (helical) in the spline on the interconnecting shaft where the cross is installed. This twist causes a interference fit between the interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting shaft. This design eliminates the clearance between the cross and the interconnecting shaft resulting in quieter operation of the driveshaft assembly. This design though eliminated the capability of removing the outer C/V joint from the interconnecting shaft. For this reason the driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft and vibration damper) in the event of a outer C/V joint boot failure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5189 Wheel Bearing: Description and Operation The rear hub and bearing assembly used on this vehicle is serviceable only as a complete assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort to repair it. The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are removable from the back of the rear hub/bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5190 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5191 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 5. Remove the 4 bolts attaching the hub/ bearing to the rear axle. CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5192 6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or equivalent and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or equivalent. Tighten bolt against Special Tool 8214-1 or equivalent. e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1 or equivalents. Removing Rear Hub/Bearing From Axle 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALL 1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications TORQUE SPECIFICATIONS Drive Plate-to-Crankshaft Bolts ........................................................................................................... ..................................................... 95 Nm (70 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5210 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5211 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5217 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5218 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5221 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5222 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5223 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5226 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5227 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5228 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5229 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5230 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5231 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5232 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5233 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5234 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5235 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5238 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5239 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5240 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5241 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5242 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5243 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5244 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5245 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5246 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5247 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5248 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5249 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5250 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5251 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 5254 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5258 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5259 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5265 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5266 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5267 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5276 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5277 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5278 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5284 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5285 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5290 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5291 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5292 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5298 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5299 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5302 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5303 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5304 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5305 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5306 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5307 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5316 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5321 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5322 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5323 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5329 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5334 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5335 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5336 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5337 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5338 Transmission Speed Sensor: Locations Transmission Control Components Input / Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5341 Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5342 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5359 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5360 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5361 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5362 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5363 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5364 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5365 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5366 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5369 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5370 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5371 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 5372 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Power Transfer Unit ............................................................................................................................. ........................................................ 1.2L (2.4 Pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5378 Fluid - Transfer Case: Fluid Type Specifications Power Transfer Unit Viscosity .............................................................................................................................................. .............................................................. SAE 85W-90 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5379 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5386 Transmission Solenoid Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5397 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5398 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder Technical Service Bulletin # 21-03-98 Date: 980213 A/T - MIL ON/Delayed Shifts/Shudder NO: 21-03-98 GROUP: Transmission DATE: Feb. 13, 1998 SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements MODELS: 1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA) Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX) WITH A 41TE/AE OR 42LE TRANSAXLE. DISCUSSION: New software has been released to address the following: All models: Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC generation. Following is a list of symptom/conditions made more fault tolerant: 1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in conditions with associated DTC's due to slower than expected response from the fluid. 2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd gear instead of 1st. On FJ/GS/JA/JX/NS models: 1. Improves the shift schedule while towing in hilly conditions. The driver may describe this condition as being in the wrong gear or delayed upshifts after cresting a hill. On NS/GS models: 1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2 upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more frequently as the fluid becomes hotter. 2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2 kick-down. On FJ 2.0L (non turbo) models: 1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F) degree or below fluid temperature. DIAGNOSIS: Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the above conditions are present or if the customer describes any of the conditions listed above, perform the Repair Procedure. NOTE: WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5404 REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. EQUIPMENT/PARTS REQUIRED: 1 CH6000 Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7000/7001 J1962 Cable 1 CH7010 J1962 MMC Cable 1 04669020 Label - Authorized Software Update 1 04275086 Label - Authorized Modification NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151 OR HIGHER MUST BE INSTALLED. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-50-93 0.5 Hrs. FAILURE CODE: FM - Flash Module Repair Procedure This bulletin involves selectively erasing and reprogramming the Transmission Control Module (TCM) with new software (calibration changes). 1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up. 2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen. 3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU. 4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU. 5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU. 6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the TCM. 7. The MDS will display the part number of the TCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming. If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the TCM on the vehicle and compare it to the part number displayed. If the TCM has already been updated, then another condition exists that will require further diagnosis and repair. 8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020 (Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5405 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI Label (Figure 2). 11. After the flash update is complete, verify the repair by attempting to duplicate the condition experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will be required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module Transmission Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5408 Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5409 Control Module: Locations Power Distribution Center Junction Block Power Distribution Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 5410 Fuse Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module Power Control Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5413 Control Module: Diagrams Control Module, A/T Part 1 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5414 Part 2 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5415 Part 3 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5416 Part 4 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5417 Part 5 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5418 Part 6 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5419 Part 7 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5420 Part 8 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5421 Part 9 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5422 Part 11 Of 11 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information Control Module: Description and Operation General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5425 The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the transaxle. The TCM receives information from several inputs, and selects the operational mode of the transaxle. Some of the inputs are used only by the TCM, while others are shared with other control modules on the CCD Bus. Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for operating conditions. This is to determine the desired gear range the transaxle must be operated in. The actual shift points within each shift schedule have been predetermined for the best transaxle operation, and are stored in the TCM's ROM memory. Once a TCM is installed during service, the following procedures must be performed: - Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the vehicle - Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes and final drive ratios on 1993 and newer vehicles The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the TCM learning process. The vehicle must still be driven and shifted several times in each gear range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool. NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module display on the DRB III scan tool Emission regulations require the use of two labels after a flash update: - Emission Modification Label - Emission Part Number Modification Label The following provides information on TCM identification and flash programming application: 1989 - 92 Original controllers were non-finned and are non-flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit 1993 - 95 Original controllers were finned with four heat sinks and are flashable - Replacement controllers have fins with four heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - Requires the use of Miller CH 5500 flash kit NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This TSB also lists the 1990 vehicles that require a wiring modification to pin 49. 1996 Original controllers were finned with seven heat sinks and are flashable - Replacement controllers have fins with seven heat sinks and are flashable - Unique communications on CCD Data Bus for these year models - DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the common DLC Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5426 Control Module: Description and Operation TCM Inputs General Information GENERAL INFORMATION The TCM receives input information and continuously processes this information through its logic circuits to perform all of the control functions that it is designed to perform. However, some of these control functions are internal to the TCM, while other control functions are performed when the TCM provides some type of output signal to another control device or module. The following is a description of TCM input sensors and output devices. The TCM uses various inputs to determine when to upshift or downshift and when to engage or disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous feedback data for controlling shift quality. Without any input, the TCM has no way to determine the state of the transaxle and cannot control its operation as designed. Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other components through the CCD Bus. DIRECT (HARD-WIRED) TCM INPUTS - Battery Feed - Ignition RUN Signal - Cranking Signal - Throttle Position Sensor (TPS) Signal - Engine speed signal (Distributor or DIS Crankshaft Position Sensor) - Input Speed Sensor Signal - Output Speed Sensor Signal - Transmission Range Sensor**(Includes Transmission Temperature Sensor) - Transmission Control Relay (Switched Battery) - L/R Pressure Switch Signal - 2-4 Pressure Switch Signal - O/D Pressure Switch Signal - Park/Neutral Position Switch* - PRNDL Switch* - Torque Reduction Request Line (TRD Link) INDIRECT (CCD BUS) TCM INPUTS - Target Idle Speed - Engine Coolant Temperature (ECT) Sensor - Battery Temperature Sensor* - Brake Switch - Engine and Body Identification - Engine Speed (Verifies Direct Input Engine Speed Signal) - Speed Control ON/OFF Switch - Speed Control Set Speed - A/C Clutch Engagement - Vehicle Identification Number (VIN) - Manifold Absolute Pressure (MAP) Sensor - Torque Reduction Confirmation Response - Relative Throttle Position (Beginning in 1998) *: UP TO 1995 **: BEGINNING IN 1996 Battery and Ignition (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5427 BATTERY A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced and also fed to the contact side of the Transmission Control Relay. On vehicles with an original TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in memory; therefore, a quick learn or road test is not necessary. IGNITION When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START (CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above approximately 26 volts or below 8 volts, the TCM automatically powers down which results in limp-in symptoms. Throttle Position Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5428 The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5 volt supply and ground for the sensor. Target idle speed is compared against actual engine speed to determine the learned TPS value for closed throttle idle. This is done to correct for differences in system voltage and sensor tolerances. If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts that are vehicle speed dependent. NOTE: Refer to TSB 18-13-94 if erratic shifting is evident. Input Speed Sensors and Output Speed Sensor (Hard-Wired) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5429 The input speed sensor provides information to the TCM on how fast the torque converter turbine is spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing. The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this information as input shaft rpm. This information is also compared to the output shaft speed and the engine speed signal to determine the following: - Planetary gears operating ratio - Torque converter clutch slippage - Torque converter element speed ratio The output speed sensor is located on the same side of the transaxle case as the input speed sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the output speed sensor signal is received by the TCM, the signal is compared to the input speed signal to determine gear ratio, detect clutch slippage, etc. Pressure Switches (Hard-Wired) The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits. The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the shift lever electrical signal is incorrect. Transmission Temperature Sensor (Hard-Wired) (Beginning 1996) The Transmission Temperature Sensor is used to monitor the temperature of the transmission fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based on the resistance value of the temperature sensor located in the Transmission Range Sensor (TRS). The primary temperature inputs used by the TCM are the Transmission Temperature Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be running to get accurate temperature readings. NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position switch. If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination of inputs. The calculated fluid temperature is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5430 continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF. On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a value between the battery temperature and engine coolant temperature signals received from the PCM over the CCD Bus. The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS, non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a heat transfer equation that uses engine coolant temperature, battery/ambient temperature and extended time off (if known) at start up. Transmission Shift Scheduling Once the engine is started, the TCM updates the transmission oil temperature based on the following to determine an estimated oil temperature during vehicle operation (if a calculated oil temperature is being used): - Torque converter slip speed - Vehicle speed - Engine coolant temperature - Battery/ambient temperature Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal operation. However, if a transmission oil cooler is added, a transmission is overfilled, a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be inappropriate for the current conditions. The key highlights of the various shift schedules are as follows: Extreme Cold: Oil temperature at start up below -16° F. - Goes to "Cold" schedule above - 12°F oil temperature - Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent shifts) Cold: Oil temperature at start up above - 12 ° F and below 36°F - Goes to "Warm" schedule above 40° F oil temperature - Delayed 2-3 upshift (approximately 22 - 31 MPH) - Delayed 3-4 upshift (45 - 53 MPH) - Early 4-3 coastdown shift (approximately 30 MPH) - Early 3-2 coastdown shift (approximately 17 MPH) - High speed 4-2, 3-2, 2-1 kickdown shifts are prevented - No EMCC Warm: Oil temperature at start up above 36° F and below 80° F - Goes to "Hot" schedule above 80°F oil temperature - Normal operation (upshift, kick-downs and coast-downs) - No EMCC Hot: Oil temperature at start up above 80° F - Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY) - Normal operation (upshifts, kick-downs and coast-downs) - Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH) Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F - Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH 97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F - Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature - Delayed 2-3 upshift (25 - 32 MPH) - Delayed 3-4 upshift (41 - 48 MPH) - 3rd gear FEMCC from 30 - 48 MPH - 3rd gear PEMCC from 27 - 31 MPH Super Overheat: 97 MY - Oil temperature above 240°F - Goes back to "Overheat" below 240 ° F oil temperature - All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. 96 and prior MY - Oil temperature above 260°F - Goes back to "Overheat" below 260 ° F oil temperature Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5431 - All "Overheat" shift schedule features apply - 2nd gear PEMCC above 22 MPH - Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a 4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to 2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1 kickdown is made. Causes for operation in the wrong temperature shift schedule: Extreme Cold or Cold shift schedule at start up: - Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only) - Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only) - Defective PCM (calculated oil temperature vehicles only) - Defective sensor circuit (TRS equipped only) Overheat or Super Overheat shift schedule after extended operation: - Operation in city traffic or stop-and-go traffic - Engine idle speed too high - Stuck AIS motor - Aggressive driving in low gear - Trailer towing in OD gear position (use "3" position if frequent shifting occurs) - Cooling system failure causing engine to operate over 230° F - Engine coolant temperature stays low too long - If engine coolant temperature drops below 150° F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will cause the transmission to overheat. - A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC disengaged will cause the transmission to overheat. - Transmission fluid overfilled (TRS equipped only) - Transmission cooler or cooler lines restricted (TRS equipped only) - Defective sensor circuit (TRS equipped only) Engine Speed (Hard-Wired and CCD Broadcast) The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor, as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is required to provide immediate information for use by the TCM control logic. The CCD engine speed data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid. MAP Sensor (CCD Broadcast) The MAP Sensor provides engine load input directly to the PCM, which determines engine torque load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades. Engine Idle Speed (Hard-Wired and CCD Broadcast) The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle. Brake Switch (CCD Broadcast) The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5432 Battery/Ambient Temperature Sensor (CCD Broadcast) The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD broadcast information is used to control charging system, engine and transaxle operation. The TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the Battery Temperature signal along with engine coolant temperature to calculate the temperature. Shift Lever Position (SLP) The TCM identifies the position of the manual lever by comparing the current switch positions of the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle with the presence of an invalid or transition input code. The SLP logic function screens the input codes from the switches and provides an SLP output signal to control actual gear selection. Inputs include the codes indicated by the TRS current shift lever position, pressure switch indications and speed ratio data from the input to most of the other functions in the TCM. The identified position is stored in memory. The current switch position is determined by sensing the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated. CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed data will not agree with the expected results for shift lever position = "OD." Therefore, it is important to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes. It is extremely important that accurate shift lever position data be available to the TCM. The accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test, performed on the DRB Scan Tool, passes without fail. Torque Management Signal (CCD Broadcast) With some engines, the TCM sends a direct input, torque management request signal to: the PCM. This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque management request signal is used in order to reduce the torque applied in the 2-4 and OD clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a very short time period. The PCM sends a confirmation of the request to the TCM over the CCD Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually be set. The torque management signal is basically a 9-volt supply to the PCM. A torque management request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is called TRD link, which stands for "Torque Reduction Link." Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5433 PRNDL Switch (Hard-Wired) NOTE: Used up to 1995 (Early 96 NS) The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The TCM uses this input to determine what gear range and shift pattern to use. Park/Neutral Position Switch (Hard-Wired) NOTE: Used up to 1995 and early 96 NS The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both switches must be closed to operate the back-up lamps. Transmission Range Sensor (Hard-Wired) The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission Range Switch that are found on vehicles prior to the 1996 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5434 MY. This sensor allows for accurate transaxle gear position identification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5435 Control Module: Description and Operation TCM Outputs General Information The TCM directly controls the following: - Transmission Control Relay - Solenoid pack - Torque management requests to the PCM Additionally, the TCM broadcasts the following information over the CCD Bus for use by other vehicle control systems (Indirect Outputs): - Communication with the DRB Scan Tool for diagnostics - Shift lever position to the BCM - Shift lever position to the shift lever display - Transmission oil temperature to the PCM in order to activate the cooling fans - Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus - Limp - in Status - Transmission Temperature - In-gear position NOTE: MIL request is from the PCM. Transmission Control Relay The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal electronic circuits are all working properly. If the self-test results are good, then the TCM sends battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts, which then supply battery voltage to the TCM, the four solenoids and the three pressure switches in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then stored in memory. The Transmission Control Relay is located in various places depending on the vehicle model. Solenoid and Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5436 When the Transmission Control Relay contact points are closed, the solenoid assembly receives electrical power. The TCM can then operate the solenoids, as determined by its programming. The relay provides power to all four solenoids through a single wire. This means that all the solenoids have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids, however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is needed. The assembly is mounted to the outside of the transaxle case, under a sound shield protective cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel plate. There are also small solenoid valve filters used to protect the valves from contamination. These filters are not replaceable. If the valve body and solenoid pack have been heavily contaminated, the solenoid pack should be closely inspected to determine if it should be replaced. The solenoid pack is not a serviceable unit. The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the solenoid/valves is that they directly control the application of a clutch. In other electronically controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through normal hydraulic valving. The solenoid assembly also contains pressure switches that feed information to the TCM. Vehicle Speed Signal The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM. The PCM receives this signal and converts it to a signal that can be used by the Body Control Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent over the CCD Bus. Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5437 On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive lockout function operated by a button on the instrument panel. The lockout feature makes driving smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the transaxle may shift in and out of overdrive, causing unnecessary shifting. NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ vehicles use a momentary contact switch. Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to normal operation and turn off the overdrive lockout lamp. With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3 upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the overdrive lockout switch or selection of the "3" position. Electronic Pinion Factor A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is replaced, the electronic pinion factor must be programmed with the DRB Scan Tool. The nature of the Electronic Pinion Factor requires that certain features must be taken into consideration: - If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed when moving - Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of specification Use the following procedures to set the electronic pinion factor using the DRB Scan Tool: - Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will display the current tire size. - If the tire size is incorrect, depress the Enter key and then select the correct size. - Depress the Page Back key to exit the reset procedure. Shifter/Ignition Interlock The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The interlock system locks the floor mounted shift lever into the PARK position whenever the ignition switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK position. Shift Position Indicator The shifter position indicator is located in the instrument cluster. The shifter position indicator outlines with a box the gear position the transaxle manual valve lever is in. The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster. Autostick Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using before Autostick was activated. Moving the shifter to the left (towards the driver) causes a downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift schedule. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page 5438 Automatic Overrides Some shifts are executed automatically or prevented Automatic shifts will occur under the illustrated conditions: Additionally, under certain circumstances, the TCM may take over and override the autostick features, for example, under the following conditions: - Autostick switch input errors - Error overspeed - Engine overheating - Transmission overheating Autostick shifts are not permitted under the illustrated conditions: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information Control Module: Service and Repair General Information Do not interchange Transmission Control Modules with previous-year transmission control modules. If a same year TCM is being used from a different vehicle, the following procedures must be performed: - Quick Learn Procedure - Electronic Pinion Procedure The Transmission Control Module is located on the right fender inner panel, in the engine compartment. It is held in place by four mounting screws. NOTE: If the Transmission Control Module has been replaced, the following procedures must be performed: - Quick Learn Procedure: This procedure will allow the transmission control module to learn the characteristics of the vehicle. - Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for different tire sizes and final drive ratios. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 5441 Control Module: Service and Repair Replacement NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner. REMOVAL 1. Disconnect the battery negative cable. 2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect the 60 way connector on Transmission Control Module. 3. Remove Transmission Control Module mounting screws and lift module from vehicle. INSTALLATION To install, reverse removal procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5445 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5446 Transmission Control Relay Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams Transmission Range Sensor (TRS) Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5452 Transmission Mode Switch: Description and Operation PARK/NEUTRAL POSITION SWITCH INPUT (ATX) Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to the Powertrain Control Module (PCM) on gearshift position. Circuit T41 connects to cavity 76 of the PCM. TRANSMISSION RANGE SENSOR (TRS) The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor provides the Transmission Control Module (TCM) with information on shift lever position, contains the transmission temperature sensor, and contains the switch for the back-up lamps. Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the NEUTRAL/OVERDRIVE or LOW position. Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position. Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE, NEUTRAL, or LOW position. Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL position. This circuit is also the ground circuit for the coil side of the engine starter motor relay. The TRS is case grounded to the transmission. Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block. When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1 circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive (AWD) solenoids, if equipped. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5453 Transmission Mode Switch: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. 12. Remove TRS retaining screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5454 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5463 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5464 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5465 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5471 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5472 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5477 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5478 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5479 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change NUMBER: 21-04-99 GROUP: Transmission DATE: Feb. 26, 1999 SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range Sensor (TRS) OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year and lists which parts are needed when service is required. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 - 1999 (PR) Prowler NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE. THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT INCLUDE THE NEW TRS. DISCUSSION: A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles. The original plan was to include these transaxles in 1999 vehicles at the start of production, but was actually implemented as a running change during the 1999 model year. NOTE: EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998 TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO DIRECTLY FIT THE 1998 TRS. This running change can cause confusion due to the differences seen within the 1999 model year or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5485 The above information will help technicians and parts personnel select the proper parts when working with these different combinations. NOTE: THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON. CAUTION: 1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR SIZE (THROUGH CASE DIAMETER). The following guidelines will help determine which components are required when making related repairs: 1999 Vehicle Needs A TRS Or Valve Body Assembly ^ Inspect the TRS for terminal type. ^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service. ^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service. 1999 Vehicle Needs A Transaxle ^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a 1999 vehicle. NOTE: IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999 TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT WOULD BE REQUIRED. 1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly ^ Order 1998 components for the transaxle. 1998 Or Earlier Vehicle Needs A Transaxle ^ If the applicable model year transaxle is ordered and received, no further action is required. ^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n 5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5486 NOTE: THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL CONNECTOR (FIGURE 1). PARTS REQUIRED: POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly Transmission Solenoid And Pressure Switch Assembly Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5489 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5490 Transmission Position Switch/Sensor: Locations 4 Speed A/T Automatic Transmission Electrical Connections (4 Speed) Switch mounted in transaxle, (automatic only). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5491 Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5492 Transmission Position Switch/Sensor: Description and Operation The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5493 Transmission Position Switch/Sensor: Service and Repair NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the transaxle oil pan and valve body must be removed. REMOVAL 1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube. 3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts. 10. Extract park rod from guide bracket and remove valve body from transaxle. 11. Place valve body on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5494 12. Remove TRS retaining screw. 13. Remove manual shaft seal. 14. Slide Transmission Range Sensor up the manual shaft and remove. INSTALLATION For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.). Reseal transaxle oil pan using RTV. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 5503 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5508 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5509 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5510 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5516 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement Technical Service Bulletin # 21-07-98 Date: 980424 A/T - 41TE/AE 42LE Delayed Gear Engagement NO: 21-07-98 GROUP: Transmission DATE: Apr. 24, 1998 SUBJECT: Delayed Transaxle Engagement THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084). THE COMPLETE BULLETIN HAS BEEN REVISED. MODELS 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1998 (FJ) Sebring/Avenger/Talon 1996 - 1998 (GS) Chrysler Voyager (European Market) 1995 - 1998 (JA) Cirrus/Stratus/Breeze 1996 - 1998 (JX) Sebring Convertible 1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE. POLICY: Information Only Symptom/Condition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5521 Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold or hot based on the table as shown. NOTE: VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED BY THE INFORMATION IN THIS BULLETIN. NOTE: WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY. Diagnosis Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test 1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine the reason for delayed engagement. NOTE: TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF VEHICLE AND DTC'S APPLY. NOTE: THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE FIELD. Item 1 DTC 35 Loss of Prime If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC 35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC 35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the pump will require replacement. NOTE: DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35 COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5522 Item 2 L - R Inner and Outer Seals Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for the bump complaint. Stop bump will be the first symptom seen before experiencing delayed engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer seals along with the piston retainer. Background: The original L - R inner and outer seals were made from an AEM (Vamac) material and were of a lip seal design. The AEM lip seals would take a compression set due to high operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals are currently being used and are the seals of choice. Item 3 UD Inner Lip Seal Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range only). Additionally, this condition may cause launch shudder. When overhauling the transaxle, make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with the piston retainer. Background: The original UD inner seal was made from AEM which had the same characteristics as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM material. The FKM UD lip seal was implemented in transaxles with a build date of XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of choice. NOTE: THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL WILL BE AEM AND MUST BE CHANGED TO FKM. NOTE: THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON. Item 4 General Seal Statement The seals within the transaxle are critical to its performance. Seals that have taken a set are not able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their location, place them back onto the component from which they were removed. Do they have slight interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and will require replacement. In addition, seals that have taken a set can be detected using a pressure check during a cold start. The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test, the vehicle must sit until cold. Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year of transaxle being worked on, replacing all seals to assure the latest seal composition is installed throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a transaxle recondition procedure is performed. NOTE: MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL MATERIAL COMPOSITION. Item 5 Measuring # 1 Check Ball Clearance If the check ball does not have the appropriate amount of clearance, it may stick in the pocket when the transaxle is hot. NOTE: THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5523 Remove the valve body and use a dial caliper to check the distance between the top of the # 1 check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the application. Item 6 PRNDL Switch (Non TRS) 41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures where moisture collects in the switch and freezes. When this occurs the transaxle may have a delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement to correct this condition. Item 7 Output Speed Sensor While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also, see TSB 08-07-94 Rev. B. Intermittent noise may cause reverse block logic to be activated. Look for output speed during a park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated. If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the condition is intermittent, or has been fixed, the output speed reading may be latched above 400 RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into reverse. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5524 Transmission Speed Sensor: Specifications Input Speed Sensor ............................................................................................................................. ...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor ..................................... ........................................................................................................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5525 Transmission Speed Sensor: Locations Transmission Control Components Input / Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector Input Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5528 Output Speed Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5529 Transmission Speed Sensor: Service and Repair CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Input (Turbine) Speed Sensor INPUT The input speed sensor is located to the left of the manual shift lever. CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not fall off or remain in old sensor. Output Speed Sensor OUTPUT The output speed sensor is located to the right of the manual shift lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5535 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5536 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5537 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5538 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5539 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5540 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5541 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5542 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5543 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5544 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5545 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5546 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5547 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5548 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5549 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5550 Transmission Temperature Sensor/Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5551 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5552 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5553 Transmission Control System (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor The transmission range sensor (on the valve body) sends a signal to the TCM on the position of the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then outlines with a box the appropriate shifter position indicator in the instrument cluster. If a problem arises with the shifter position indicator, consult the following chart for diagnostic information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic chart in Transmission Control Systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5556 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Description and Operation Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5557 The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor > Page 5558 Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature Sensor - Circuit Operation CIRCUIT OPERATION The transmission temperature sensor is used to monitor the temperature of the transmission fluid. The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS). Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The T54 circuit connects to cavity 54 of the TCM connector. Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and output speed sensor. This circuit connects to cavity 13 of the TCM connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 5559 Transmission Temperature Sensor/Switch: Testing and Inspection Chrysler does not provide a procedure to test the transmission temperature sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on the right side of the message center located at the top of the instrument panel. The purpose of the warning lamp is discussed in detail below. The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function or when the body controller does not receive C2D messages from the CAB. When the ignition key is turned to the on position, the ABS Warning Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on, only the ABS function of the brake system is affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. The ABS warning lamp is controlled by the CAB and the body controller through a diode located in the wiring harness junction block. The junction block is located under the instrument panel to the left of the steering column. The CAB and the body controller, controls the yellow ABS warning lamp by directly grounding the circuit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the junction block. On vehicles equipped with traction control, the fuse for the traction control switch is also located in the junction block. The junction block is located on the left hand front cowl panel on the vehicle. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER There are two brake fluid accumulators in the Hydraulic Control Unit (HCU). There is one brake fluid accumulator for the primary and secondary hydraulic circuits. The brake fluid accumulators temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This stored brake fluid is then used by the pump in the HCU to provide build pressure for the brake hydraulic system. Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a mini brake fluid accumulator on the secondary hydraulic circuit which protects the master cylinder's seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit. On ABS equipped vehicles with traction control, in addition to the brake fluid accumulators there are also two noise damping chambers in the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Diagrams > Page 5574 Brake Fluid Pump: Description and Operation Integrated Control Unit (ICU) The Hydraulic Control Unit (HCU) contains 2 pump assemblies, one for the primary and one for the secondary hydraulic circuit of the brake system. Both pumps are driven by a common electric motor which is part of the HCU. The pumps draw brake fluid from the fluid accumulators to supply build pressure to the brakes during an ABS stop. The pump motor runs during the drive-off cycle as a check and during an ABS stop and is controlled by the Controller Antilock Brake (CAB). The Pump/Motor Assembly is not a serviceable item. If the pump/motor requires replacement the complete HCU (minus the CAB) must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations NOTE: The diagnostics of the ITT Teves Mark 20 ABS system is performed using the DRB scan tool. ABS BRAKE DIAGNOSTIC TOOL CONNECTOR Diagnostic Scan Tool Data Link Connector On this vehicle, the diagnostic connector used for the diagnosis of the ITT Teves Mark 20 ABS system is located under the lower steering column cover, to the left side of the steering column, just below the hood release lever. The ITT Teves Mark 20 ABS system uses the ISO 9141-K connector which is shared by other vehicle diagnostic systems such as the powertrain control module and air bag electronic control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 5578 Diagnostic Connector - ABS: Description and Operation NOTE: The diagnostics of the ITT Teves Mark 20 ABS system is performed using the DRB scan tool. ABS BRAKE DIAGNOSTIC TOOL CONNECTOR Diagnostic Scan Tool Data Link Connector On this vehicle, the diagnostic connector used for the diagnosis of the ITT Teves Mark 20 ABS system is located under the lower steering column cover, to the left side of the steering column, just below the hood release lever. The ITT Teves Mark 20 ABS system uses the ISO 9141-K connector which is shared by other vehicle diagnostic systems such as the powertrain control module and air bag electronic control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5582 Controller Antilock Brakes Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5583 Controller Antilock Brakes Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications > Page 5584 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch - Traction Control Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Ten Valves With Traction Control - Diagnostic Communication - Body Controller Communication - Traction Control Lamp Illumination Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control Unit (HCU). 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. CAB 25 Way Connector Unlocking CAB 25 Way Connector 4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of the HCU. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake tubes. 5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5587 Brake Tube Connections To HCU 6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. HCU To Suspension Cradle Mounting Bolts 7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember. 8. Remove HCU and the mounting bracket as a unit from the vehicle. HCU Mounting Bolts 9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5588 Pump Motor To CAB Wiring Harness 10. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 11. Remove the 4 bolts attaching the CAB to the valve block of the HCU. Remove/Install CAB 12. Remove the CAB from the valve block of the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5589 Electronic Brake Control Module: Service and Repair Installation Remove/Install CAB 1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit (HCU). CAB Attaching Bolts 2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). Pump Motor To CAB Wiring Harness 3. Plug the pump/motor wiring harness into the CAB. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5590 HCU Mounting Bolts 4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front suspension crossmember. HCU To Suspension Cradle Mounting Bolts 5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Brake Tube Connections To HCU Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5591 CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. 6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. Unlocking CAB 25 Way Connector 7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. Brake Tube Routing Clips 8. Install the routing clips on the brake tubes. 9. Lower vehicle. 10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bracket To Suspension Cradle Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) To Mounting Bracket Isolator Attaching Bolts ..................................................................................................................................... 11 Nm (97 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5595 Hydraulic Control Assembly - Antilock Brakes: Locations Teves Mark 20 ICU Hydraulic Control Unit (Integrated) Mounting Location Located behind the steering rack on the left side of the suspension crossmember. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information Teves Mark 20 ICU The Hydraulic Control Unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used on previous Chrysler products with ABS. The HCU used on this ABS system is part of the Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from previous Chrysler products with ABS, where the HCU and the CAB were separate components located in different areas of the vehicle. Teves Mark 20 ABS uses two different HCU's and CAB's depending on the type of ABS system the vehicle is equipped with. There is a unique HCU and CAB for a vehicle equipped with just ABS and a unique HCU and CAB for a vehicle equipped with ABS and traction control. NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS. ICU Mounting Location The ICU is located on the driver's side of the vehicle, and is mounted to the front suspension cradle. The ABS only ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four outlet valves) fluid accumulators a pump, and an electric motor. The ABS with traction control ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking and traction control operation: The CAB, four solenoid controlled inlet valves, four solenoid controlled outlet valves, two hydraulic shuttle valves, two ASR valves, fluid accumulators a pump and an electric motor. Also attached to the hydraulic control unit are the master cylinder primary and secondary brake tubes and the brake tubes going to each wheel of the vehicle. CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is diagnosed as not functioning properly it MUST be replaced. The replaceable components of the ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate component of the ICU. The remaining components of the ICU are not serviceable items. No attempt should ever be made to remove or service any individual components of the HCU. This is due to the concern of contamination entering the HCU while performing a service procedure. Also no attempt should ever be made to remove or service any individual components of the CAB. CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any electrical connector of the HCU or the CAB. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 5598 Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two accumulators, and pump/motor assembly. Located behind the steering rack on the left side of the suspension crossmember. Valve Block Assembly The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On JX and NS Bodies which are equipped with a traction control system, there are two additional valves that isolate the master cylinder and rear wheels. During a traction control situation the brakes are applied to reduce wheel slippage. Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the accumulators during the next drive off. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB monitors the pump/motor operation internally. Accumulators The accumulators provide temporary fluid storage during an antilock stop and are drained by the pump/motor. Each of the diagonal circuits uses a 5cc. accumulator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 5599 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids INLET VALVES AND SOLENOIDS There are four inlet solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been completed the inlet solenoids will return to their released (open) position. OUTLET VALVES AND SOLENOIDS There are four outlet solenoids, one for each wheel. In the released position they are closed to allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel brakes of the vehicle to the hydraulic control unit HCU accumulators and pump motor. The outlet solenoids are spring loaded in the released (closed) position during normal braking. ASR VALVE (ABS WITH TRACTION CONTROL ONLY) On vehicles equipped with ABS having traction control, there are two special ASR valves located in the HCU portion of the ICU. The ASR valves are a normally open type valve and are solenoid actuated. The special ASR valves are used to isolate the rear (non-driven) wheels of the vehicle from the hydraulic pressure that the HCU pump motor is sending to the front (driven) wheels, when the traction control system is in operation. The rear brakes need to be isolated from the master cylinder when traction control is in operation so that the HCU can build the required hydraulic pressure to the front brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control Unit (HCU). 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAB 25 Way Connector 4. Remove the routing clip attaching the HCU wiring harness to the HCU mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. Unlocked 25 Way CAB Connector 5. Remove the 25 way connector from the Controller Antilock Brake (CAB). The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5602 Brake Tube Connections To HCU 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. HCU To Suspension Cradle Mounting Bolts 8. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember. 9. Remove HCU and the mounting bracket as a unit from the vehicle. HCU Mounting Bolts 10. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket. 11. Remove the CAB from the bottom of the HCU for installation on the replacement HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5603 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation CAB 25 Way Connector 1. Install the Controller Antilock Brake (CAB) on the bottom of the Hydraulic Control Unit (HCU). HCU Mounting Bolts 2. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front suspension crossmember. HCU To Suspension Cradle Mounting Bolts 3. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5604 crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. Brake Tube Connections To HCU CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. 4. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. Unlocked 25 Way CAB Connector 5. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the HCU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 6. Clip the cab wiring harness to the HCU mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5605 Brake Tube Routing Clips 7. Install the routing clips on the brake tubes. 8. Lower vehicle. 9. Connect negative cable back on negative post of the battery. 10. Bleed the base brakes and the ABS brakes hydraulic system. 11. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection The traction control light is tested by cycling the traction control switch on and off. The traction control switch used on this vehicle is a momentary contact type switch. The test procedure for the traction control light is performed as follows: Press the traction control switch once and the "Trac Off" lamp will illuminate. With the "Trac Off" lamp illuminated, press the traction control switch again and the "Trac Off" lamp will turn off. If the traction control lamp does not function as described in the test above, diagnosis of the traction control switch, lamp, wiring and other related components of the traction control system is required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Harness Side Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 5613 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 5614 Traction Control Switch: Testing and Inspection REMOVAL AND INSTALLATION Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Refer to Switch Continuity Table. Switch Continuity Table Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Diagrams > Page 5615 Traction Control Switch: Service and Repair Over Steering Column Bezel REMOVAL 1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control switch to the bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 900 - 1,300 ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 5620 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Air Gap 0.014 - 0.059 in Rear Air Gap 0.020 - 0.054 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 5623 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 5626 Wheel Speed Sensor: Diagrams Rear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 5627 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable. The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on the rear driveshaft. The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear driveshaft outboard constant velocity joint. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles to occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 5628 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5631 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5632 Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5633 Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Rear Wheel Speed Sensor Attaching Bolt 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5634 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5635 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5636 Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or equivalent. Position Driver, Special Tool 6908-1 or equivalent with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5637 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5642 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5643 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Bleeding Teves Mark 20 Hydraulic System The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications Pedal Ratio .......................................................................................................................................... ............................................................................ 3.36 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5651 94 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5652 95 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5653 Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5654 244 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5655 245 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 5656 Brake Warning Indicator: Description and Operation The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank position. The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank position. The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that brake fluid level in the master cylinder fluid reservoir has dropped to below normal. This may indicate: (1) Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. (2) Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level sensor closes to ground the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5666 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5667 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5668 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5669 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5670 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5676 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5677 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5678 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5679 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5680 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5681 Brake Caliper: Specifications Bore Diameter 60 mm Caliper Mounting Bolts 16 ft.lb Guide Pin Bolts 30 ft.lb Bleeder Screw 125 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Page 5682 Brake Caliper: Testing and Inspection CLEANING AND INSPECTION Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front CAUTION: During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove the 2 caliper to steering knuckle guide pin bolts. Caliper Assembly Mounting On Steering Knuckle (Typical) 4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5685 Storing Front Disc Brake Caliper 5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex hose. Supporting weight of caliper by the brake fluid flex hose, can damage the flexible brake hose. INSTALL 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper end of caliper over the machined abutment on steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 3. Install the caliper guide pin bolts and tighten to a torque of 55 Nm (40 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the wheel and tire assembly 5. Using a torque wrench, tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. Rear GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of rotor. Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. If inspection reveals that the caliper piston seal is leaking, it MUST be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5686 Removing Caliper Guide Pin Bolts 3. Remove the disc brake caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. INSTALL NOTE: Step 1 below is only required when installing the disc brake caliper after new brake shoes have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5687 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. 5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 8. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5688 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly and Assembly DISASSEMBLY WARNING: Under no condition should air pressure ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the First inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston fram opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5689 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5690 ASSEMBLY CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise (with protective caps installed on jaws of vise). Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5691 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171 or equivalents, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Guide Pin Bushing Service NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5692 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5693 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5694 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5695 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front Brake Pad: Specifications Front Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or less, they should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Front > Page 5700 Brake Pad: Specifications Rear Brake Shoe Thickness Measurement The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection Brake Pad: Service and Repair Cleaning and Inspection FRONT If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the shoe and lining assemblies. Combined shoe and lining thickness should be measured at the thinnest part of the brake shoe assembly. When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it should be replaced. Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that both front wheel brake shoe assembly sets be replaced, whenever shoe assemblies on either side of the vehicle require replacement. If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is returned to its original position. REAR If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the calipers. Remove the rear disc brake shoes. The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly. When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch) they should be replaced. Replace both brake shoe assemblies (inboard and outboard). It is necessary that both rear wheel sets be replaced whenever brake shoe assemblies on either side are replaced. If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure each brake shoe is returned to the original position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection > Page 5703 Brake Pad: Service and Repair Front REMOVE WARNING: Although factory installed brake linings are made from asbestos free materials, some after market brake lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle. Always wear a respirator when cleaning brake components as asbestos can cause serious bodily harm such as asbestosis and or cancer. Never clean brake components by using compressed air, use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner is not available, clean brake parts using only water-dampened shop towels. Do not create brake lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended safety practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA), for handling and disposal of products containing asbestos. CAUTION: During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. Removing Outboard Brake Pad From Caliper 1. Remove outboard brake pad, by prying the pad retaining clip over raised area on caliper. Then slide the pad down and off the caliper. Removing Inboard Brake Pad From Piston 2. Pull inboard brake pad away from piston, until retaining clip on brake pad is free from cavity in caliper piston. INSTALL 1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for caliper installation with new brake pad assemblies. 2. Remove the protective paper from the noise suppression gasket on both the inner and outer brake pad assemblies (if equipped). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection > Page 5704 Front Brake Shoe Assembly Identification NOTE: The inboard and outboard brake pads are not common, refer to image for inboard and outboard brake pad assembly identification. Inboard Brake Shoe 3. Install the new inboard brake pad assembly into the caliper piston by firmly pressing into piston bore. Be sure inboard brake pad assembly is positioned squarely against face of caliper piston. Installing Outboard Brake Shoe 4. Slide the new outboard brake pad assembly onto the caliper assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection > Page 5705 Brake Pad: Service and Repair Rear WARNING: Although factory installed brake linings are made from asbestos free materials, some after market brake lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle. Always wear a respirator when cleaning brake components as asbestos can cause serious bodily harm such as asbestosis and or cancer. Never clean brake components by using compressed air, use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner is not available, clean brake parts using only water-dampened shop towels. Do not create brake lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended safety practices prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA), for handling and disposal of products containing asbestos. GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. Handling of the braking disc and caliper is to be done in such a way as to avoid deformation of the disc and scratching or nicking of brake linings. If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it MUST be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Removing Caliper Guide Pin Bolts 3. Remove the caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection > Page 5706 Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 6. Remove the rear rotor from the hub by pulling it straight off the wheel mounting studs. 7. Remove the outboard brake shoe from the caliper. Brake shoe is removed by prying brake shoe retaining clip over raised area on caliper and sliding the brake shoe off the caliper. Removing Inboard Brake Pad From Piston 8. Remove inboard brake shoe from caliper. Inboard brake shoe is removed by pulling it out of the caliper piston, until the retaining clip is free of the piston. CALIPER INSPECTION Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if scored). Check the caliper dust boot and caliper pin bushings to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. INSTALL NOTE: Step 1 below is only required when installing a caliper after new brake shoes have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Cleaning and Inspection > Page 5707 Inboard Brake Shoe 4. Install the inboard brake shoe into the caliper piston by firmly pressing it into the piston bore using your thumbs. Be sure inboard brake shoe is positioned squarely against the face of the caliper piston. 5. Install the outboard brake shoe on the disc brake caliper CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 6. Carefully lower caliper and brake shoes over rotor and onto adapter, reversing the removal procedure CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to cross-thread the guide pin bolts. 7. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 8. Install the wheel and tire assembly. 9. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 10. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop the vehicle. 11. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Brake Rotor Specifications Brake Rotor Specifications BRAKE ROTOR Front Rear BRAKE ROTOR TYPE Ventilated Solid BRAKE ROTOR DIAMETER (14"/15" Standard) 260 mm (10.24 in.) 381 mm (15.0 in.) BRAKE ROTOR DIAMETER (15" Heavy Duty) 283 mm (117.92 in.) ----ROTOR THICKNESS 23.87 - 24.13 mm (0.939 - 0.949 in.) 12.25 - 12.75 mm (0.482 - 0.502 in.) MINIMUM ROTOR THICKNESS 22.4 mm (0.881 in.) 11.25 mm (0.443 in.) Minimum allowable thickness markings are cast/stamped on an un-machined outer surface of the rotor. These thickness markings include 0.76 mm (0.030 in.) allowable rotor wear beyond the recommended 0.76 mm (0.030 in.) of rotor refacing. ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.) ROTOR RUNOUT * 0.08 mm (0.003 in.) 0.08 mm (0.003 in.) * TIR - Total Indicator Reading (measured on vehicle) ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS Front Rotor Thickness Markings Rear Rotor Thickness Markings Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5711 Brake Rotor/Disc: Testing and Inspection GENERAL INFORMATION Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. Before refinishing or refacing a rotor, the rotor should be checked and inspected for the following conditions: Braking surface scoring, rust, impregnation of lining material and worn ridges. Excessive rotor lateral runout or wobble. Thickness variation in braking surface of the rotor (Parallelism). Dishing or distortion in braking surface of the rotor (Flatness). If a vehicle has not been driven for a period of time, the rotors will rust in the area not covered by the brake lining and cause noise and chatter when the brakes are applied. Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed from braking surface of rotor before installation of new brake shoe assemblies. Some discoloration and/or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This will also increase guide pin bushing wear due to the tendency of the caliper to follow rotor wobble. Thickness variation in a rotor can also result in pedal pulsation, chatter and surge due to variation in brake output. This can also be caused by excessive runout in the rotor and/or the hub. Dishing or distortion can be caused by extreme heat and abuse of the brakes. CHECKING ROTOR FOR RUNOUT AND THICKNESS NOTE: The procedure for checking rotor runout and thickness is the same for the front and rear rotor. If there is a specification difference between the front and rear rotor it will be designated as such in the specifications of the following procedure. Checking Brake Rotor For Runout On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor run-outs are separable). To measure runout on the vehicle, remove the wheel and reinstall the lug nuts tightening the rotor to the hub. Mount Dial Indicator, Special Tool C-3339 with Mounting Adaptor, Special Tool SP-1910 or equivalent on steering arm. Dial indicator plunger should contact braking surface of rotor approximately 10 mm (0.393 inch) from outer edge of rotor. Check lateral runout on both sides of rotor. Lateral runout of the rotor should not exceed 0.13 mm (0.005 inch). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5712 Marking Rotor And Wheel Stud If lateral runout is in excess of the specification, check the lateral runout of the hub face. Before removing rotor from hub, make a chalk mark across both the rotor and one wheel stud on the high side of the runout. This will ensure that the original location of the rotor in relation to the hub can be retained. Remove rotor from hub. Checking Disc Brake Rotor For Runout Thoroughly clean the front surface of the front hub. Then install Dial Indicator, Special Tool C-3339 and Mounting Adaptor, Special Tool SP-1910 or equivalent on steering knuckle. Position stem so it contacts hub face near outer diameter. Care must be taken to position stem outside the stud circle but inside the chamfer on the hub face. Clean hub surface before checking. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5713 Indexing Rotor And Wheel Stud Lateral runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the hub must be replaced. See Steering and Suspension. If lateral runout of the hub does not exceed this specification, install rotor on hub with chalk marks two wheel studs apart. Tighten nuts in the proper sequence and torque to specification. Finally, check lateral runout of rotor to see if lateral runout is now within specification. Minimum Rotor Thickness Markings If lateral runout is not within specification, install a new rotor or reface rotor, being careful to remove as little rotor material as possible from each side of rotor. Remove equal amounts from each side of rotor. Do not reduce thickness below minimum thickness marking cast into the un-machined surface of the rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5714 Checking Rotor For Thickness Variation Thickness variation measurements of the rotor should be made in conjunction with the lateral runout measurements. Measure the thickness of the rotor at 12 circumferentially equal points with a micrometer at a radius approximately 25.4 mm (1 inch) from outer edge of rotor. If thickness measurements vary by more than 0.013 mm (0.0005 inch), rotor should be removed and resurfaced, or a new rotor installed. If cracks or burned spots are evident, rotor must be replaced. Light scoring and/or wear is acceptable. If heavy scoring or warping is evident, the rotor must be refinished or replaced (See Refinishing/Refacing Rotor). If cracks are evident in the rotor, replace the rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5715 Brake Rotor/Disc: Service and Repair Rotor Refinishing Limits Specifications Rear Rotor Thickness Markings Fig 6 Refacing Brake Disc Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5716 Fig 7 Refacing Brake Disc -- Final Finish PROCEDURES Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be resurfaced, refaced or replaced. NOTE: Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. This marking includes 0.76 mm (0.030 inch) allowable rotor wear beyond the recommended 0.76 mm (0.030 inch) of rotor refacing. The collets, shafts and adapters used on the brake lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. When mounting the rotor on the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. If the rotor is not mounted properly, the lateral runout will be worse after refacing or resurfacing than before. REFACING BRAKE ROTOR Refacing of the rotor is not required each time the brake pads are replaced. When refacing a rotor the required 0.08 mm (0.003 inch) Total Indicated Runout (TIR) and 0.013 mm (0.0005 inch) thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. The use of a double straddle cutter that machines both sides of the rotor at the same time is highly recommended. RESURFACING BRAKE ROTOR This operation can be used when rotor surface is rusty, has lining deposits or excessive lateral runout or thickness variation is evident. A sanding rotor attachment will remove surface contamination without removing much rotor material. It will generally follow variations in thickness that are in the rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5722 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5723 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5724 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5725 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5726 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5727 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5728 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 5729 Backing Plate: Specifications To Rear Axle Mounting Bolts ............................................................................................................... ................................................. 130 Nm (95 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 5730 Backing Plate: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove brake shoes from brake support plate. 5. Disconnect the park brake cable from the park brake actuation lever. 6. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 7. Remove the 4 bolts attaching the hub/ bearing to the flange of the rear axle. CAUTION: Corrosion may occur between the hub/bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/bearing. This damage will result in noise or failure of the bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 5731 8. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or equivalent and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the bole in the bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or equivalent. Tighten bolt against Special Tool 8214-1 or equivalent. e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1 or equivalents. 9. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 5732 10. Using a suitable tool such as a 14 mm box wrench or an aircraft type hose clamp, compress the flared legs on park brake cable retainer. Then pull the park brake cable out of brake support plate. 11. Lower vehicle enough to access the brake pedal. 12. Using a brake pedal depressor, move brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. 13. Raise vehicle. 14. Disconnect brake tube from wheel cylinder. 15. Remove the 2 bolts attaching the wheel cylinder to the brake support plate. 16. Remove the wheel cylinder from the brake support plate. 17. Remove the rear brake support plate from the rear axle. INSTALL 1. Install the 4 hub/bearing to axle mounting bolts into the mounting holes in the flange of the rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 5733 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. NOTE: When installing the hub/bearing on the rear axle, the bearing is to be installed with the thick bearing mounting flange pointing down. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Apply sealant such as Mopar Gasket-In-A-Tube or an equivalent around the wheel cylinder opening in the brake support plate. 6. Install wheel cylinder onto brake support and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 7. Install brake tube on rear wheel cylinder. Tighten tube nut to a torque of 16 Nm (142 inch lbs.). 8. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 9. Install the rear park brake cable into its mounting hole in the rear brake support plate. 10. Install the park brake cable on the park brake actuation lever. 11. Install the rear brake shoes on the brake support plate. 12. Install brake drum onto hub/bearing. 13. Install wheel and tire. 14. Tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 15. Adjust the rear brakes. 16. Bleed the entire brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection Brake Adjuster: Testing and Inspection ADJUSTER REAR DRUM BRAKE (AUTOMATIC) The rear drum brakes on this vehicle automatically adjust, when required, during the normal operation of the vehicle every time the brakes are applied. Use the following procedure to test the operation of the automatic adjuster. Place the vehicle on a hoist with a helper in the driver's seat to apply the brakes. Remove the access plug from the adjustment hole in each brake support plate to provide visual access of the brake adjuster star wheel. Park Brake Cable Equalizer Remove the park brake cable, for the wheel of the vehicle that is being worked on, from the park brake cable equalizer. This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel. To eliminate the condition where maximum adjustment of the rear brake shoes, does not allow the automatic adjuster to operate when tested, back the star wheel off approximately 30 notches. It will be necessary to hold the adjuster lever away from the star wheel to permit this adjustment. Have the helper apply the brakes. Upon application of the brake pedal, the adjuster lever lever should move down, turning the adjuster star wheel. Thus, a definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly. If one or more adjusters do not function properly, the respective drum must be removed for adjuster servicing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5741 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5742 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5743 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5744 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5745 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5746 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5747 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 5748 Brake Drum: Specifications Brake Drum Specifications Brake Drum Specifications DRUM DIAMETER 250 mm (9.84 in.) DRUM DIAMETER (Maximum) Cast/stamped into outside surface of drum This marking includes 0.76 mm (0.030 inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing. DIAMETER VARIATION (Maximum) 0.090 mm (0.004 in.) DRUM RUNOUT (on lathe) 0.15 mm (0.006 in.) INITIAL DRUM MACHINING CUTS 0.13 mm (0.005 in.) Initial machining cuts should be limited to 0.13 mm (0.005 in.) at a time as heavier feed rates can produce taper and surface variation. FINISH DRUM MACHINING CUTS 0.0254 mm (0.001 in.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation Brake Drum: Service and Repair Brake Drum Removal and Installation REMOVE Park Brake Cable Equalizer 1. Remove the tire and wheel assembly from the vehicle. Remove the park brake cable, for the wheel of the vehicle that is being worked on, from the park brake cable equalizer. This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel. 2. Remove the rear brake shoe adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 4. Insert Tool C-3784 or equivalent into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake adjustment by prying down with adjusting tool. 5. Remove rear brake drum from rear hub/bearing assembly. INSTALL 1. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 2. Install the rear brake drums on the hubs. 3. Adjust rear brake shoes. 4. Install the removed park brake cable back on the park brake cable equalizer 5. Install wheel and tire. 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 130 Nm (95 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal and Installation > Page 5751 Brake Drum: Service and Repair Brake Drum Refinishing Measure the runout and diameter of the rear brake using only accurate measuring equipment. There should be no variation in the drum diameter greater than 0.090 mm (0.004 inch). Drum runout should not exceed 0.15 mm (0.006 inch) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced. For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.13 mm (0.005 inch). When the entire braking surface has been cleaned. A final cut of 0.0254 mm (0.001 inch) will assure a good drum surface providing the equipment used is capable of the precision required for resurfacing brake drums. Deeper cuts are permissible for the sole purpose of removing deep score marks. Do not reface more than 1.52 mm (0.060 inch) over the standard drum diameter. All drums will show markings of maximum allowable diameter. For example, a drum will have a marking of MAX. DIA. 251.55 mm (9.90 inch). This marking includes 0.76 mm (0.030 inch) for allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5756 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5757 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5758 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5759 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5760 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5761 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5762 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5763 Brake Shoe: Specifications As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal WARNING: Although factory installed brake linings are made from asbestos free materials, some aftermarket brake lining may contain asbestos. This should be taken into account when servicing a vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle. Always wear a respirator when cleaning brake components as asbestos can cause serious bodily harm such as asbestosis and or cancer. Never clean brake components by using compressed air, use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner is not available, clean brake parts using only water-dampened shop towels. Do not create brake lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended safety practices; prescribed by the Occupational Safety And Health Administration (OSHA) and the Environmental Protection Agency (EPA), for handling and disposal of products containing asbestos. 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire assemblies from the vehicle. 3. Remove rear brake drum to hub retaining nuts (if equipped). Then remove rear brake drums from hub and bearing assemblies. NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, be sure that the park brake pedal is in the released (most upward) position. 4. Create slack in the rear park brake cables. Slack is created by grabbing exposed section. of front park brake cable and pulling it down and rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the park brake cable just rearward of only the rear body outrigger bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5766 5. Remove adjustment lever spring from adjustment lever and front brake shoe. 6. Remove adjustment lever from leading brake shoe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5767 7. Remove the brake shoe to brake shoe lower return springs. 8. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly. 9. Remove the brake shoe to brake shoe upper return spring. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5768 10. Remove the trailing brake shoe assembly to brake support plate hold down spring and pin from the brake shoe assembly. 11. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and park brake actuating strut. Remove the automatic adjuster assembly from the leading brake shoe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5769 12. Remove the leading brake shoe assembly to brake support plate hold down spring and pin from the brake shoe. Remove the leading brake shoe from the brake support plate. 13. Remove the park brake actuator from the leading brake shoe and transfer to the replacement brake shoe. Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5770 1. Lubricate the eight shoe contact areas on the support plate and anchor, using the required special Mopar Brake Lubricant, P/N 4796269. 2. Install leading brake shoe on brake support plate. Install the leading brake shoe hold down spring and pin on the brake shoe. 3. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5771 4. Install the automatic adjuster screw on the leading brake shoe. Then install the trailing brake shoe on the park brake actuating lever and park brake actuating strut. Position trailing brake shoe on brake support plate. 5. Install the brake shoe hold down pin and spring on the trailing brake shoe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5772 6. Install the brake shoe to brake shoe upper return spring. CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the threaded area of the adjuster assembly. If it is located on a non-threaded area of the adjuster, the function of the automatic adjuster will be affected. 7. Install the tension clip attaching the upper return spring to the automatic adjuster assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5773 8. Install the brake shoe to brake shoe lower return springs on the brake shoes. 9. Install automatic adjustment lever on the leading brake shoe of the rear brake assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5774 10. Install the actuating spring on the automatic adjustment lever and leading brake shoe assembly. 11. Verify that the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 12. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 13. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 14. Install the rear brake drums on the hubs. 15. Adjust rear brake shoes. 16. Install the wheel and tire assembly. 17. Push the park brake pedal to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the park brake cables. 18. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 130 Nm (95 ft. lbs.). 19. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 5775 Brake Shoe: Service and Repair Cleaning and Inspection 1. Remove the tire and wheel assembly from the vehicle Brake Adjustment Hole Rubber Plug 2. Remove the rear brake adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. 4. Insert Tool C-3784 or equivalent into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake by prying down with adjusting tool. 5. Remove the rear brake drum from the rear hub/bearing assembly. 6. Inspect brake lining for wear, shoe alignment, and or contamination from grease or brake fluid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Diameter 3/4 in To Support Plate Mounting Bolts 75 in.lb Bleeder Screw 80 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 5779 Rear Wheel Cylinder (Exploded View) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid.) 2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel cylinder attaching bolts. Then pull wheel cylinder assembly off the brake support plate. INSTALL 1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5782 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5783 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; (DO NOT USE ANY PETROLEUM BASE SOLVENTS) clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.) 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with only Mopar Protect-A-Cup Lubricant p/n 04883068 and no substitute. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures Bleeding Base Brake Hydraulic System NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake System bleeding procedure in antilock brakes. Pressure Bleeding Procedure CAUTION: - Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. - Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding. - When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system is pressurized. Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment. Air Trapped In Brake System When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. 1. Remove the filler neck from the master cylinder fluid reservoir. Pressure Bleeding Cap Installed On Master Cylinder 2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the fluid reservoir of the master cylinder. Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent. 3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5789 adequate removal of all trapped air from the brake hydraulic system. (1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel Rear Wheel Cylinder Bleeder Screw 4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid discharge will NOT get all the air out. 5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Bleeding Without A Pressure Bleeder NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are correctly adjusted. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. - Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5790 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Bleeding Teves Mark 20 Hydraulic System The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake hydraulic system needs to be bled. It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal. During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add DOT 3 brake fluid as required. The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS portion of the brake system is to be bled the same as any non ABS system. This brake system can be either pressure bled or manually bled. The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below. ABS BLEEDING PROCEDURE When bleeding the ABS system, the following bleeding sequence MUST be followed to insure complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure or standard pressure bleeding equipment. If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base Brakes. 1. Assemble and install all brake system components on the vehicle making sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the instrument panel to the left of the steering column cover. 3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault codes stored. If it does, remove them using the DRB. WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be attached to the bleeder screws and submerged in a clear container filled part way with clean brake fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed ABS" cycle one time. Release the brake pedal. 6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6 above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir periodically to prevent reservoir from running low on brake fluid. 8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5799 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5800 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5801 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5802 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5803 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear Technical Service Bulletin # 05-003-01 Date: 010420 Brakes - Howl/Moan From The Rear NUMBER: 05-003-01 GROUP: Brakes DATE: Apr. 20, 2001 SUBJECT: Off Pedal Rear Brake Howl/Moan OVERVIEW: This bulletin involves replacing the rear disc brake adapters. MODELS: 1997 - 2000 (NS) Voyager/Caravan/Town & Country 1997 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Voyager/Caravan/Town & Country 2001 (RG) Chrysler Voyager (International Markets) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD). SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from the rear brake area. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Could be one or more Repair Procedure 1. Apply the parking brake and raise the vehicle on an appropriate hoist. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5809 2. Remove right rear tire and wheel assembly. 3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V joint (Fig. 1). 4. Remove the hub nut and washer from the stub shaft of the outer CV joint. 5. Mark the driveshaft inner joint location to the rear driveline module flange. 6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline module (Fig. 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5810 7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3). 8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is removed by first compressing the inner joint on the driveshaft and removing it from the driveline module. Then, slide the outer joint of the driveshaft out of the hub and bearing. 9. Release the parking brake. 10. Create slack in the rear parking brake cables by locking out the automatic adjuster as described. Grasp the exposed section of the front park brake cable and pull downward on it. Then install a pair of locking pliers on the front brake cable just rearward of the second body out rigger bracket (Fig. 4). 11. Remove the park brake cable from the adapter by: a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the park brake cable. b. RS/RG vehicles: removing the park brake mounting bolt. 12. Remove the end of the park brake cable from the actuator lever on the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5811 13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer. 14. Remove the disc brake caliper to adapter guide pin bolts. 15. Remove caliper from the adapter using the following procedure: a. Rotate rear of caliper up. b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. 16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose. 17. Remove the rotor from the hub/bearing. 18. Remove the four hub/bearing to axle mounting bolts. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER. 19. Remove the hub/bearing from the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5812 20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two cannot be separated by hand, use the following procedure: a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1 on the cast housing of the hub/bearing (Fig. 6) NOTE: DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING. b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the caliper adapter. 21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any part that is damaged or worn must be replaced by new parts. 22. Remove the park brake hardware (including the rubber access plug) from the adapter and install park brake hardware on the new adapter. 23. Install the new adapter on the axle. 24. Install the hub/bearing on the end of the axle. 25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4 mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle. Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.). 26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching bolt to 12 Nm (105 in. lbs.). 27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output shaft of the driveline module. Do not tighten mounting bolts at this time. 28. Install the park brake cable into its mounting hole in the adapter. NOTE: BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER. 29. Install the end of the park brake cable on the park brake actuator lever. 30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable mounting bolt to the adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The Rear > Page 5813 31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake shoe to park brake drum clearance. 32. Install rotor on hub/bearing. 33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper adapter by reversing the removal procedure in step 15. CAUTION: WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS. 34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts. Torque to 22 Nm (192 in. lbs.). 35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle. 37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and torquing the hub nut and driveshaft inner joint to driveline module mounting bolts. 38. Raise the vehicle. 39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a torque of 61 Nm (45 ft. lbs.). 40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.). 41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V joint. 42. Install tire and wheel assembly. 43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.). 44. Replace the left rear adapter using steps 2 through 43. 45. Lower the vehicle. 46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5814 Brake Caliper: Specifications Bore Diameter 60 mm Caliper Mounting Bolts 16 ft.lb Guide Pin Bolts 30 ft.lb Bleeder Screw 125 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Page 5815 Brake Caliper: Testing and Inspection CLEANING AND INSPECTION Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if scored. Check the guide pin dust boots to determine if they are in good condition. Replace if they are damaged, dry, or found to be brittle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Front CAUTION: During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies. 3. Remove the 2 caliper to steering knuckle guide pin bolts. Caliper Assembly Mounting On Steering Knuckle (Typical) 4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering knuckle. Then slide opposite end of caliper out from under machined abutment on steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5818 Storing Front Disc Brake Caliper 5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex hose. Supporting weight of caliper by the brake fluid flex hose, can damage the flexible brake hose. INSTALL 1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper end of caliper over the machined abutment on steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 3. Install the caliper guide pin bolts and tighten to a torque of 55 Nm (40 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the wheel and tire assembly 5. Using a torque wrench, tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal. Rear GENERAL INFORMATION During service procedures, grease or any other foreign material must be kept off brake shoe assemblies, and braking surfaces of rotor. Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. If inspection reveals that the caliper piston seal is leaking, it MUST be replaced immediately. During removal and installation of a wheel and tire assembly, use care not to strike the caliper. REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies from vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5819 Removing Caliper Guide Pin Bolts 3. Remove the disc brake caliper to adapter guide pin bolts. Removing/Installing Caliper 4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. INSTALL NOTE: Step 1 below is only required when installing the disc brake caliper after new brake shoes have been installed. 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5820 3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. 5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 8. Remove jackstands or lower hoist. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5821 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly and Assembly DISASSEMBLY WARNING: Under no condition should air pressure ever be used to remove a piston from a caliper bore. Personal injury could result from such a practice. 1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic fluid cannot get on rotor. Place a small piece of wood between the piston and caliper fingers. 2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold down the brake pedal to any position beyond the First inch of pedal travel. This will prevent loss of brake fluid from the master cylinder. 3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at frame rail. Plug brake tube and remove piston fram opposite caliper using the same process as above for the first piston removal. 4. Disconnect the brake fluid flex hose from the caliper assembly. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston. 5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin sleeves and guide pin bushings. Fig. 10 Dust Boot Removal 7. Remove the piston dust boot from the caliper and discard. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5822 Removing Piston Seal From Caliper 8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston bore. Discard old seal. Do not use a screw driver or other metal tool for this operation, because of the possibility of scratching piston bore or burring edges of seal groove. 9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint residue can remain in caliper bore. Clean out all drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must be installed at assembly. Honing Brake Caliper Piston Bore 10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone, Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than 0.0254 mm (0.001 inch). 11. If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary brush. NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time. CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced. 12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is evidence of scratches, pitting or physical damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5823 ASSEMBLY CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 1. Clamp caliper in a vise (with protective caps installed on jaws of vise). Installing New Piston Seal In Caliper 2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled. 3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position dust boot over piston after coating with brake fluid. CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper. Installing Piston Into Caliper Bore 5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6. Position dust boot into the counterbore of the caliper assembly piston bore. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5824 7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171 or equivalents, drive boot into counterbore of the caliper. 8. Install guide pin sleeves and bushings. 9. Install brake pads. 10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly. 11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs.). New seal washers MUST always be used when installing brake hose to caliper. 12. Bleed the brake system. Guide Pin Bushing Service NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this assembly can be serviced using the following procedure. REMOVING CALIPER GUIDE PIN BUSHINGS 1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5825 Removing Inner Sleeve From Bushing 2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown. Removing Bushing From Caliper 3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing. INSTALLING CALIPER GUIDE PIN BUSHINGS Folded Caliper Guide Pin Bushing 1. Fold the bushing in half lengthwise at the solid middle section of the bushing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5826 Installing Caliper Guide Pin Bushing 2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step due to possible damage to the bushing. Bushing Correctly Installed In Caliper 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. Flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an equivalent. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5827 Fig 7 Installing Caliper Sleeves 5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing through boot until one end of bushing is fully seated into seal groove on one end of sleeve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 5828 Fig 8 Installed Caliper Bushing Sleeve 7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on sleeve. Be sure other end of bushing did not come out of seal grove in sleeve. 8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5832 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Page 5833 Brake Fluid: Service and Repair FLUID LEVEL CHECK Check master cylinder reservoir fluid level a minimum of twice annually. Master Cylinder Fluid Level Marks Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of the fluid reservoir with brake fluid. Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3, specifications. DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid ect. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Description and Operation Brake Fluid Accumulator: Description and Operation HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER There are two brake fluid accumulators in the Hydraulic Control Unit (HCU). There is one brake fluid accumulator for the primary and secondary hydraulic circuits. The brake fluid accumulators temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This stored brake fluid is then used by the pump in the HCU to provide build pressure for the brake hydraulic system. Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a mini brake fluid accumulator on the secondary hydraulic circuit which protects the master cylinder's seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit. On ABS equipped vehicles with traction control, in addition to the brake fluid accumulators there are also two noise damping chambers in the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5840 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level sensor. Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level sensor. Master Cylinder Brake Fluid Level Sensor 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid reservoir. 5. Connect the vehicle wiring harness connector to the brake fluid level sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications To Caliper Banjo Bolt ........................................................................................................................... ................................................... 48 Nm (35 ft. lbs.) Intermediate Bracket .......................................... ................................................................................................................................. 12 Nm (105 inch lbs.) Tube Nuts To Fittings And Components ............................................................................................................................................. 17 Nm (145 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5844 Brake Hose/Line: Description and Operation The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 5845 Brake Hose/Line: Testing and Inspection Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual deterioration of the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting in wheel, tire, or chassis interference. The steel brake tubing should be inspected periodically for evidence of physical damage or contact with moving or hot components. The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the master cylinder to the ABS hydraulic control unit connections and the chassis brake tubes between the hydraulic control unit and the proportioning valve must also be inspected. This flexible tubing must be inspected for kinks, fraying and its contact with other components of the vehicle or contact with the body of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring General Information CAUTION: When repairing brake chassis lines or flex hoses, the correct fasteners must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach components to the front suspension cradle have an anti-corrosion coating due to the suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion coating are to be used if a replacement fastener is required when installing a brake chassis line or flex hose. Only double wall 4.75 mm (3/16 inch) steel tubing with Al-rich/ZW-AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm (15/64 inch). These tubes are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same anti-corrosion coating. Be sure the correct tube nuts are used for the replacement of these hydraulic brake tubes. Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. If the primary or secondary brake line from the master cylinder to the ABS Hydraulic Control Unit, or the flexible brake lines between the hydraulic control unit and the proportioning valve require replacement only the original factory brake lines containing a flexible section can be used. This is required due to the movement of the front suspension cradle while the vehicle is in motion. Cutting And Flaring Of Brake Fluid Tubing Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5848 Tube End Properly Prepared For Flaring Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square and ensure better seating of flared end tubing. PLACE TUBE NUT ON TUBING BEFORE FLARING THE TUBING. Double Inverted Tubing Flares Inverted Flare And ISO Flare Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5849 Inverted Double Wall Flare And ISO Flare Tubing Connections To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or equivalent. Then rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Refer to tube routing diagrams for proper brake tube routing and clip locations. Replace any damaged tube routing clips. ISO Tubing Flares Inverted Flare And ISO Flare Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5850 Inverted Double Wall Flare And ISO Flare Tubing Connections CAUTION: All ISO style tubing flares are of metric dimensions. When performing any service procedures on vehicles using ISO style tubing flares, metric size tubing of 4.75 mm MUST be used with metric ISO tube flaring equipment. To create a (metric) ISO style tubing flare, Use Snap-On Flaring Tool TFM-428, or equivalent. See image and proceed with the steps listed below. Be sure to place the tubing nut on the tube before flaring the tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5851 Tube End Properly Prepared For Flaring 1. Carefully prepare the end of the tubing to be flared. Be sure the end of the tubing to be flared is square and all burrs on the inside of the tubing are removed. This preparation is essential to obtain the correct form of a (metric) ISO tubing flare. 2. Open jaws of the Flaring Tool. Align the mating size jaws of the flaring tool around the Size of the tubing to be flared. Close the jaws of the Flaring Tool around the tubing to keep it from sliding out of the flaring tool, but do not lock the tubing in place. 3. Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the flaring tool bar assembly. 4. Install the correct size adaptor for the brake tubing being flared, on the feed screw of the yoke assembly. Center the yoke and adapter over the end of the tubing. Apply lubricant to the adapter area that contacts brake tubing. Making sure the adapter pilot is fully inserted in the end of the brake tubing. Screw in the feed screw of the yoke assembly until the adaptor has seated squarely on the surface of the bar assembly. This process has created the (metric) ISO tubing flare. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5852 Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement CAUTION: When installing brake chassis lines or flex hoses on the vehicle, the correct fasteners must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach components to the front suspension cradle have an anti-corrosion coating due to the suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion coating are to be used if a replacement fastener is required when installing a brake chassis line or flex hose. Only double wall 4.75mm (3/16 inch) steel tubing with Al-rich/ZW-AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube. NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm (15/64 inch). These tubes are also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same anti-corrosion coating. Be sure that the correct tube nuts are used for the replacement of these hydraulic brake tubes. Care should be taken when replacing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips. If the primary or secondary brake tube from the master cylinder to the ABS Hydraulic Control Unit (HCU) or the brake tubes from the HCU to the proportioning valve require replacement, only the original factory brake line containing the flexible section can be used as the replacement part. This is required due to cradle movement while the vehicle is in motion. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes Brake Proportioning/Combination Valve: Specifications With Antilock Brakes FIXED PROPORTIONING VALVE: To Frame Rail Attaching Bolts ........................................................................................................................................................ 14 Nm (125 inch lbs.) HEIGHT SENSING PROPORTIONING VALVE: To Mounting Bracket Attaching Bolts ............................................................................................................................................ 23 Nm (200 inch lbs.) Actuator Assembly Adjustment Nut .................................................................................................................................................... 5 Nm (45 inch lbs.) Mounting Bracket To Frame Rail Bolts .......................................................................................................................................... 17 Nm (150 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Specifications > With Antilock Brakes > Page 5857 Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes FIXED PROPORTIONING VALVE: To Frame Rail Attaching Bolts ........................................................................................................................................................ 14 Nm (125 inch lbs.) HEIGHT SENSING PROPORTIONING VALVE: To Mounting Bracket Attaching Bolts ............................................................................................................................................ 23 Nm (200 inch lbs.) Actuator Assembly Adjustment Nut .................................................................................................................................................... 5 Nm (45 inch lbs.) Mounting Bracket To Frame Rail Bolts .......................................................................................................................................... 17 Nm (150 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve Brake Proportioning/Combination Valve: Description and Operation Fixed Proportioning Valve DESCRIPTION The hydraulic brake system on all vehicles is diagonally split. This means that the left front and right rear brakes are on one hydraulic circuit with the right front and left rear brakes on the other hydraulic circuit. On vehicles equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is mounted to the front suspension crossmember on the driver's side of the vehicle. The HCU acts as the hydraulic system junction block, diagonally splitting the brakes hydraulic system. Fixed Proportioning Valve Location All vehicles equipped with ABS brakes use 2 fixed proportioning valves. The fixed proportioning valves are mounted in a common bracket on the left frame rail at the rear of the vehicle. OPERATION The fixed proportioning valve is made out, of aluminum and has an integral mounting bracket. The fixed proportioning valve is non-serviceable component and must be replaced as an assembly if found to be functioning improperly. The fixed proportioning valve is mounted to the bottom of the left rear frame rail, just forward of the rear shock absorber to frame rail mounting location. The proportioning valve has 2 inlet ports for brake fluid coming from the ABS modulator, and 2 outlet ports for brake fluid going to the rear wheel brakes. The fixed proportioning valve operates by allowing full hydraulic pressure to the rear brakes up to a set point, called the valve's split point. Beyond this split point the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio. Thus, on light brake pedal applications the proportioning valve allows approximately equal brake hydraulic pressure to be supplied to both the front and rear brakes. On heavier brake pedal applications though, the proportioning valve will control hydraulic pressure to the rear brakes, so that hydraulic pressure at the rear brakes will be lower than that at the front brakes. This controlled hydraulic pressure to the rear brakes prevents excessive rear wheel ABS cycling during moderate stops. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 5860 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve Proportioning Valve Mounting Location One assembly containing two proportioning valves are used in the system, one for each rear brake hydraulic circuit. The proportioning valve is located on the frame rail next to the fuel tank, forward of the right rear shock absorber. Be sure replacement proportioning valve assemblies have the same split point and slope as the proportioning valve being replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5861 Brake Proportioning/Combination Valve: Testing and Inspection On a vehicle equipped with ABS, premature or excessive rear wheel ABS cycling may be an indication that the brake fluid pressure to the rear brakes is above the desired output. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining material specification. The vehicles brake system is not balanced for after market brake shoe assembly lining material. If brake shoe assembly lining material is of satisfactory condition, and of the correct material specification, check for proper proportioning valve function using the following procedure. Rear Brake Proportioning Valve And Brake Tube Locations 1. Road test vehicle to be sure the vehicle is truly exhibiting a condition of excessive rear wheel ABS cycling. Since ABS cycles both rear brakes together both proportioning valves of the assembly must be tested. Use the following procedure to test the proportioning valve. 2. Remove one of the chassis brake lines coming from the ABS modulator, at 3. the proportioning valve assembly. Remove the hydraulic brake line going to one of the rear wheels of the vehicle from the proportioning valve. 4. Remove the 2 bolts attaching the proportioning valve to the frame rail. CAUTION: When lowering the proportioning valve, care must be taken not to kink any of the chassis brake lines. 5. Carefully lower the proportioning valve for clearance to install the proportioning valve test fittings. Proportioning Valve Test Fitting Installation 6. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the inlet port of the proportioning valve assembly, from which the chassis brake line was removed. Install the removed chassis brake line into the Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5862 Pressure Gauges Installed On Pressure Test Fittings 7. Install a pressure gauge from Gauge Set, Special Tool C-4007-A or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that rear wheel cylinder. 8. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. 9. Repeat steps 2 through 7 for the other proportioning valve of the assembly. CAUTION: When mounting the original or a replacement proportion valve on the frame rail of the vehicle install the mounting bolts in only the two forward holes of the mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes NOTE: The actual proportioning valves of the proportioning valve assembly are not serviceable or replaceable. If a proportioning valve of the proportioning valve assembly is not functioning properly, the fixed proportioning valve must be replaced as an assembly. REMOVE 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. 2. Raise vehicle on jackstands or centered on a hoist. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. Chassis Brake Tubes At Proportioning Valve 3. Remove the 4 chassis brake lines from the inlet and outlet ports of the proportioning valve. Proportioning Valve Attachment To Vehicle 4. Remove the bolts attaching the proportioning valve bracket to the frame rail of the vehicle. Remove the fixed proportioning valve assembly from the vehicle. INSTALL CAUTION: When mounting the original or a replacement proportioning valve on the frame rail of the vehicle install the mounting bolts in only the two forward holes of the mounting bracket. 1. Install proportioning valve assembly on the frame rail of the vehicle. Install the proportioning valve assembly attaching bolts. Tighten the attaching bolts to a torque of 14 Nm (125 inch lbs.). 2. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve assembly. Tighten all 4 line nuts to a torque of 16 Nm (142 inch lbs.). 3. Bleed the brake system thoroughly enough to ensure that all air has been expelled from the hydraulic system. 4. Lower the vehicle to the ground. 5. Road test the vehicle to verify proper operation of the vehicles brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 5865 Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes NOTE: The components of the proportioning valve assembly are not serviceable or replaceable. If a component of the proportioning valve assembly is not functioning properly, the proportioning valve must be replaced as an assembly. REMOVE 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. 2. Raise vehicle on jackstands or centered on a hoist. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. Chassis Brake Tubes At Proportioning Valve 3. Remove the 4 chassis brake tubes from the inlet and outlet ports of the proportioning valve. Proportioning Valve Mounting 4. Remove the 2 bolts attaching the proportioning valve to the proportioning valve mounting bracket. Remove the proportioning valve from the mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > With Antilock Brakes > Page 5866 Actuator Attachment To Proportioning Valve 5. Remove the hooked end of the proportioning valve actuator from the isolator bushing on the lever of the height proportioning valve. INSTALL 1. Install the hooked end of the actuator on the proportioning valve lever. Be sure isolator bushing on lever of proportioning valve is fully seated in hook of actuator. NOTE: When installing height sensing proportioning valve on mounting bracket be sure proportioning valve shield is installed between the proportioning valve and the mounting bracket. 2. Install height sensing proportioning valve on mounting bracket. Install the proportioning valve attaching bolts. Tighten the attaching bolts to a torque of 23 Nm (200 inch lbs.). 3. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve. Tighten all 4 line nuts to a torque of 16 Nm (142 inch lbs.). 4. Adjust the proportioning valve actuator. 5. Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. 6. Lower the vehicle to the ground. 7. Road test the vehicle to verify proper operation of the vehicles brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Mounting Bracket To Suspension Cradle Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) To Mounting Bracket Isolator Attaching Bolts ..................................................................................................................................... 11 Nm (97 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 5870 Hydraulic Control Assembly - Antilock Brakes: Locations Teves Mark 20 ICU Hydraulic Control Unit (Integrated) Mounting Location Located behind the steering rack on the left side of the suspension crossmember. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information Teves Mark 20 ICU The Hydraulic Control Unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used on previous Chrysler products with ABS. The HCU used on this ABS system is part of the Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from previous Chrysler products with ABS, where the HCU and the CAB were separate components located in different areas of the vehicle. Teves Mark 20 ABS uses two different HCU's and CAB's depending on the type of ABS system the vehicle is equipped with. There is a unique HCU and CAB for a vehicle equipped with just ABS and a unique HCU and CAB for a vehicle equipped with ABS and traction control. NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS and traction control has a valve block housing that is approximately 1 inch longer on the low pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS. ICU Mounting Location The ICU is located on the driver's side of the vehicle, and is mounted to the front suspension cradle. The ABS only ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four outlet valves) fluid accumulators a pump, and an electric motor. The ABS with traction control ICU contains the following components for controlling the brake system hydraulic pressure during ABS braking and traction control operation: The CAB, four solenoid controlled inlet valves, four solenoid controlled outlet valves, two hydraulic shuttle valves, two ASR valves, fluid accumulators a pump and an electric motor. Also attached to the hydraulic control unit are the master cylinder primary and secondary brake tubes and the brake tubes going to each wheel of the vehicle. CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is diagnosed as not functioning properly it MUST be replaced. The replaceable components of the ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate component of the ICU. The remaining components of the ICU are not serviceable items. No attempt should ever be made to remove or service any individual components of the HCU. This is due to the concern of contamination entering the HCU while performing a service procedure. Also no attempt should ever be made to remove or service any individual components of the CAB. CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any electrical connector of the HCU or the CAB. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 5873 Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two accumulators, and pump/motor assembly. Located behind the steering rack on the left side of the suspension crossmember. Valve Block Assembly The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On JX and NS Bodies which are equipped with a traction control system, there are two additional valves that isolate the master cylinder and rear wheels. During a traction control situation the brakes are applied to reduce wheel slippage. Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the accumulators during the next drive off. The pump mechanism consists of two opposing pistons operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB monitors the pump/motor operation internally. Accumulators The accumulators provide temporary fluid storage during an antilock stop and are drained by the pump/motor. Each of the diagonal circuits uses a 5cc. accumulator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 5874 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids INLET VALVES AND SOLENOIDS There are four inlet solenoids, one for each wheel. In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been completed the inlet solenoids will return to their released (open) position. OUTLET VALVES AND SOLENOIDS There are four outlet solenoids, one for each wheel. In the released position they are closed to allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel brakes of the vehicle to the hydraulic control unit HCU accumulators and pump motor. The outlet solenoids are spring loaded in the released (closed) position during normal braking. ASR VALVE (ABS WITH TRACTION CONTROL ONLY) On vehicles equipped with ABS having traction control, there are two special ASR valves located in the HCU portion of the ICU. The ASR valves are a normally open type valve and are solenoid actuated. The special ASR valves are used to isolate the rear (non-driven) wheels of the vehicle from the hydraulic pressure that the HCU pump motor is sending to the front (driven) wheels, when the traction control system is in operation. The rear brakes need to be isolated from the master cylinder when traction control is in operation so that the HCU can build the required hydraulic pressure to the front brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control Unit (HCU). 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAB 25 Way Connector 4. Remove the routing clip attaching the HCU wiring harness to the HCU mounting bracket. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. Unlocked 25 Way CAB Connector 5. Remove the 25 way connector from the Controller Antilock Brake (CAB). The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise and unlock the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5877 Brake Tube Connections To HCU 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. HCU To Suspension Cradle Mounting Bolts 8. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember. 9. Remove HCU and the mounting bracket as a unit from the vehicle. HCU Mounting Bolts 10. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket. 11. Remove the CAB from the bottom of the HCU for installation on the replacement HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5878 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation CAB 25 Way Connector 1. Install the Controller Antilock Brake (CAB) on the bottom of the Hydraulic Control Unit (HCU). HCU Mounting Bolts 2. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front suspension crossmember. HCU To Suspension Cradle Mounting Bolts 3. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5879 crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. Brake Tube Connections To HCU CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. 4. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. Unlocked 25 Way CAB Connector 5. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the HCU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 6. Clip the cab wiring harness to the HCU mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5880 Brake Tube Routing Clips 7. Install the routing clips on the brake tubes. 8. Lower vehicle. 9. Connect negative cable back on negative post of the battery. 10. Bleed the base brakes and the ABS brakes hydraulic system. 11. Road test vehicle to ensure proper operation of the base and ABS systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Specifications Hydraulic System Junction Block: Specifications Junction Block Mounting Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Specifications > Page 5884 Hydraulic System Junction Block: Service and Repair REMOVE 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block. 2. Raise vehicle on jackstands or centered on a hoist. CAUTION: Before removing the brake tubes from the junction block, the junction block and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the brake hydraulic system. 3. Remove the 6 chassis brake tubes from the junction block. 4. Remove the bolt attaching the junction block mounting bracket to the front suspension cradle. INSTALL 1. Install the junction block and mounting bracket on the front suspension cradle. Install the attaching bolt and tighten to a torque of 28 Nm (250 inch lbs.). 2. Install the 6 chassis brake tubes into the inlet and outlet ports of the junction block. Tighten all 6 tube nuts to a torque of 16 Nm (145 inch lbs.). 3. Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. 4. Lower the vehicle. 5. Road test the vehicle to verify proper operation of the vehicles brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation Load Compensator: Description and Operation DESCRIPTION CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. Junction Block Location On vehicles not equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is replaced by a junction block. The junction block is made of aluminum and is mounted to the front suspension crossmember on the drivers side of the vehicle in the same location as the HCU on an ABS equipped vehicle. The junction block is permanently attached to its mounting bracket and must be replaced as an assembly with its mounting bracket. The junction block is used for diagonally splitting the brake's hydraulic system. Height Sensing Proportion Valve Operation Vehicles not equipped with ABS brakes use a height sensing proportioning valve. The height sensing proportioning valve is mounted on the left frame rail at the rear of the vehicle. The height sensing proportioning valve uses an actuator assembly to attach the proportioning valve to the left rear spring for sensing changes in vehicle height. OPERATION The height sensing proportioning valve regulates the hydraulic pressure to the rear brakes. The proportioning valve regulates the pressure by sensing the load condition of the vehicle through the movement of the proportioning valve actuator assembly. The actuator assembly is mounted between the height sensing proportioning valve and the actuator bracket on the left rear leaf spring. As the rear height of the vehicle changes depending on the load the vehicle is carrying the height change is transferred to the height sensing proportioning valve. This change in vehicle height is transferred through the movement of the left rear leaf spring. As the position of the left rear leaf spring changes this movement is transferred through the actuator bracket to the actuator assembly and then to the proportioning valve. Thus, the height sensing proportioning valve allows the brake system to maintain the optimal front to rear brake balance regardless of the vehicle load condition. Under a light load condition, hydraulic pressure to the rear brakes is minimized. As the load condition of the vehicle increases, so does the hydraulic pressure to the rear brakes. The proportioning valve section of the valve operates by transmitting full input hydraulic pressure to the rear brakes up to a certain point, called the split point. Beyond the split point the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio. Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to the front and rear brakes. At heavier brake applications, the hydraulic pressure transmitted to the rear brakes will be lower then the front brakes. This will prevent premature rear wheel lock-up and skid. The height sensing section of the valve thus changes the split point of the proportioning valve based on the rear suspension height of the vehicle When the height of the rear suspension is low, the proportioning valve interprets this as extra load and the split point of the proportioning valve is Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation > Page 5888 raised to allow more rear braking. When the height of the rear suspension is high, the proportioning valve interprets this as a lightly loaded vehicle and the split point of the proportioning valve is lowered and rear braking is reduced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation > Page 5889 Load Compensator: Testing and Inspection CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. When a premature rear wheel skid is obtained on a brake application, it may be an indication that the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve. This condition indicates a possible malfunction of the height sensing proportioning valve, which will require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear brakes. Premature rear wheel skid may also be caused by an incorrectly adjusted proportioning valve actuator assembly, or contaminated front or rear brake linings. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining material specification. The vehicles brake system is not balanced for after market brake shoe assembly lining material. If both front and rear brakes check OK, proceed to verify that the actuator assembly for the height sensing proportioning valve is adjusted correctly. Refer to Adjustments. If the proportioning valve is adjusted correctly, proceed with the test procedure for the height sensing proportioning valve as follows: Actuator Assembly Adjustment Nut 1. Remove the actuator assembly adjustment nut. Remove the actuator assembly from the lever on the height sensing proportioning valve. Brake Tube Connections To Proportioning Valve 2. Remove the chassis brake tube coming from the junction block from the front of the height sensing proportioning valve. Remove the chassis brake tube going to the rear brakes from the back of the height sensing proportioning valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation > Page 5890 Proportioning Valve Test Fitting Installation Proportioning Valve Test Fitting Installation 3. Install the required fittings from Pressure Test Fittings, Special Tool 6833 or equivalent into the inlet port of the proportioning valve assembly, from which the chassis brake line was removed. Install the removed chassis brake line into the Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the proportioning valve. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting. Pressure Gauges Installed On Pressure Test Fittings 4. Install a pressure gauge from Gauge Set, Special Tool C-4007-A or equivalent into each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being tested, at that rear wheel cylinder. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation > Page 5891 5. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then based on the type of brake system the vehicle is equipped with and the pressure specification shown on the table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. 6. Remove the pressure test fittings and pressure gauges from the proportioning valve. 7. Install the chassis brake lines in the correct ports of the proportioning valve. 8. Install the pressure test fittings and pressure gauges in the opposite inlet and outlet port of the height sensing proportioning valve. Repeat steps 4 and 5 for the other proportioning valve. 9. Remove the pressure test fittings and pressure gauges from the proportioning valve. 10. Install the chassis brake lines in the correct ports of the proportioning valve. 11. Install the actuator on the height sensing proportioning valve. Adjust the proportioning valve actuator. Refer to Adjustments. 12. Bleed both rear hydraulic circuits at the rear brakes. 13. Road test vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Description and Operation > Page 5892 Load Compensator: Adjustments Proportioning valve actuator adjustment will be required if there is a complaint of premature rear wheel lockup and the front and rear brake shoe linings checked OK during inspection, the height sensing proportioning valve required replacement, or there is a complaint of excessive pedal effort and the vacuum booster and brake pedal checked OK. Make sure the proportioning valve and the mounting bracket are firmly attached to the vehicle. Then, proceed with the following procedure to perform the adjustment of the actuator. 1. Raise vehicle. Vehicle is to be raised and supported on jackstands or with a frame contact type hoist so the rear suspension of the vehicle is hanging free. 2. Remove rear wheels/tires. 3. Using an appropriate jack, support the rear axle prior to the removal of the track bar and shock absorber bolts from the rear axle. 4. Unbolt the track bar from the rear axle. 5. Unbolt both shock absorbers from the rear axle. 6. Loosen (do not remove) both of the leaf spring to front spring hanger pivot bolts. NOTE: When lowering the rear axle be sure that the leaf springs do not come in contact with the hoist limiting the downward movement of the axle. If this occurs an improper adjustment of the actuator may result. 7. Lower the rear axle so it is at its farthest point of downward movement. Proportioning Valve Actuator Adjustment 8. Loosen the adjustment nut on the actuator. 9. Be sure the hooked end of the actuator is correctly (fully) seated in the clip on the proportioning valve lever and that the clip is correctly positioned on the lever of the proportioning valve. 10. Pull the housing of the proportioning valve actuator toward the spring hanger until the lever on the proportioning valve bottoms on the body of the proportioning valve. Hold the proportioning valve actuator in this position while tightening the adjustment nut to a torque of 5 Nm (45 inch lbs.). Proportioning valve adjustment is now complete. 11. Install shock absorbers and track bar on rear axle. Do not tighten the mounting bolts for any of the loosened suspension components at this time. 12. Install the wheel/tires. 13. Lower the vehicle to the ground. Be sure that the suspension is supporting the full weight of the vehicle. 14. Tighten the spring to front hanger pivot bolts to a torque of 156 Nm (115 ft. lbs.). 15. Tighten the shock absorber mounting, bolts to a torque of 101 Nm (75 ft. lbs.). 16. Tighten the track bar mounting bolt to a torque of 95 Nm (70 ft. lbs.). 17. Road test vehicle to ensure that the premature rear wheel lockup condition has been corrected. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes Brake Master Cylinder: Specifications With Antilock Brakes DIMENSIONS: Bore/Stroke .................................................................................................................................................... 23.8 mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ................................................................... ................................................................................................................................. 50/50 With ABS Only: Primary Fluid Outlet Ports .......................................................................................... ........................................................................................... 7/16-24 Secondary Fluid Outlet Ports ..... .............................................................................................................................................................. .............. 7/16-24 With ABS With Traction Control: Primary Fluid Outlet Ports ............................................................... ..................................................................................................................... M12 x 1 Secondary Fluid Outlet Ports .......................................................................................................................................... ...................................... M12 x 1 TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 25 Nm (225 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > With Antilock Brakes > Page 5897 Brake Master Cylinder: Specifications Without Antilock Brakes DIMENSIONS: Bore/Stroke .................................................................................................................................................... 23.8 mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ................................................................... ................................................................................................................................. 50/50 Primary Fluid Outlet Ports ................................................................................................................................. .................................................... 7/16-24 Secondary Fluid Outlet Ports ............................................ ..................................................................................................................................... 7/16-24 TIGHTENING TORQUES: Mounting Nuts ..................................................................................................................................... ............................................ 25 Nm (225 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes Brake Master Cylinder: Description and Operation With Antilock Brakes Master Cylinder Assembly The master cylinder is a standard tandem compensation port design for ABS and non ABS systems. Traction control vehicles use a dual center port master cylinder. For proper traction control the standard master cylinder must not be used. A vehicle equipped with Teves Mark 20 ABS with Traction control uses a unique center port master cylinder. If the master cylinder is replaced on a vehicle equipped with traction control be sure the right type of master cylinder is installed. A vehicle equipped with four wheel disc brakes (AWD applications) also have a unique master cylinder. The master cylinder used on these vehicles have a piston bore diameter which is larger then the master cylinder used on the other brake applications. The primary and secondary outlet ports on the master cylinder go directly to the hydraulic control unit HCU. A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > With Antilock Brakes > Page 5900 Brake Master Cylinder: Description and Operation Without Antilock Brakes Master Cylinder Assembly The master cylinder consists of the following components. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder piston and threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir of the master cylinder assembly is made of a see through polypropylene type plastic. A low fluid switch is also part of the reservoir assembly. This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of brake system the vehicle is equipped with. If a vehicle is not equipped with antilock brakes, or is equipped with antilock brakes without traction control, a conventional compensating port master cylinder is used. If a vehicle is equipped with antilock brakes with traction control, a dual center port master cylinder is used. The third master cylinder used on this vehicle is unique to vehicles equipped with four wheel disc brakes. The master cylinder used for this brake application has a different bore diameter and stroke then the master cylinder used for the other available brake applications. The master cylinders used on front wheel drive applications (non four wheel disc brake vehicles) have a master cylinder piston bore diameter of 23.8 mm. The master cylinder used on the all wheel drive applications (four wheel disc brake vehicles) have a master cylinder piston bore diameter of 25.4 mm. When replacing a master cylinder, be sure to use the correct master cylinder for the type of brake system the vehicle is equipped with. The master cylinder is not a repairable component and must be replaced if diagnosed to be functioning improperly CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the bore. The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange, do not clamp on primary piston, seal boot or body of master cylinder. Master Cylinder Mounted In Vise 1. Clamp the master cylinder in a vise using only the mounting flange. NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder with a larger diameter brake tube. Vehicles not equipped with traction control use a compensating port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the correct size bleeding tubes are used when bleeding the master cylinder. Bleed Tubes Installed On Master Cylinder 2. Install the Bleeding Tubes, Special Tool 6920 or equivalent for a non traction control master cylinder or Special Tool 8129 or equivalent for a traction control master cylinder on the master cylinder. Position bleeding tubes so the outlets of bleeding tubes will be below surface of brake fluid when reservoir is filled to its proper level. 3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an Equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to released position. Repeat several times until all air bubbles are expelled from master cylinder. 5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap from the master cylinder filler neck, on the master cylinder fluid reservoir. 8. Install the master cylinder assembly on the power brake vacuum booster. NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the hydraulic system when the master cylinder was removed. Manual Bleeding Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5903 NOTE: - Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. - To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. - The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. Left Rear Wheel - Right Front Wheel - Right Rear Wheel - Left Front Wheel 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5904 Brake Master Cylinder: Service and Repair Master Cylinder Replacement CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with traction control use a center port master cylinder. Vehicles not equipped with traction control use a compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four wheel disc brakes have a master with a different size piston bore than the other master cylinders. If a new master cylinder is being installed, be sure the correct master cylinder is used for the type of brake system the vehicle is equipped with. REMOVE CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4 - 5 strokes). CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the brake fluid reservoir and entering the brakes hydraulic system. 2. Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Filler Tube Removal 3. Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating. Then remove the cap from the removed filler tube and install it on the master cylinder reservoir. Master Cylinder Assembly 4. Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder brake fluid reservoir. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5905 Primary/Secondary Brake Tubes At Master Cylinder 5. Disconnect the primary and secondary brake tubes from the master cylinder housing. Install sealing plugs in the open brake tube outlets on master cylinder assembly. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the power brake vacuum booster. 6. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Mounting To Vacuum Booster 7. Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster. 8. Slide master cylinder assembly straight out of the power brake vacuum booster. CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal/boot on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 9. Remove the vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from the master cylinder by carefully pulling it away from the master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the hydraulic system when the master cylinder was removed. INSTALL CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal onto the master cylinder. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5906 Vacuum Seal Installed On Master Cylinder 1. Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of master cylinder casting. 2. Position master cylinder on studs of power brake unit, aligning push rod on power brake vacuum booster with master cylinder push rod. 3. Install the 2 master cylinder to power brake unit mounting nuts. Then tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS hydraulic control module HCU and the master cylinder, when the vehicle is in motion. 4. Connect the primary and secondary brake tubes to master cylinder primary and secondary ports. Brake tubes must be held securely when tightened to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). 5. Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder brake fluid reservoir. 6. Install filler tube into the master cylinder fluid reservoir. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5907 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement 1. Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. 2. Remove the filler tube and brake fluid reservoir cap. Using a syringe or equivalent type tool empty as much brake fluid as possible from the reservoir. CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of tool. This can damage the fluid reservoir or master cylinder housing. 3. Remove the master cylinder assembly from the power brake vacuum booster. Master Cylinder Mounted In Vise 4. Mount the master cylinder in a vise using the master cylinder mounting flange. Fluid Reservoir Retaining Pins 5. Using correct size pin punch, remove the 2 retaining pins between the fluid reservoir and master cylinder housing. Rock the brake fluid reservoir from side to side while pulling up to remove it from the seal grommets in master cylinder housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5908 Master Cylinder To Fluid Reservoir Seal Grommets 6. Remove the 2 master cylinder housing to brake fluid reservoir seal grommets. 7. Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 8. Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over sealing grommets. Seat reservoir into sealing grommets using a rocking motion while firmly pressing down on fluid reservoir. 9. Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be touching the top of both sealing grommets when properly installed on master cylinder housing. 10. Install the 2 fluid reservoir to master cylinder retaining pins. 11. Install the master cylinder assembly on the power brake vacuum booster. 12. Install filler tube on the fluid reservoir. Fill fluid reservoir to its proper level as indicated on the outboard side of the fluid reservoir. Be careful not to over fill the fluid reservoir, fluid is not intended to be stored in the filler tube. Install cap on fluid reservoir filler tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5909 Brake Master Cylinder: Service and Repair Fluid Reservoir Fill Tube Replacement NOTE: The master cylinder fluid reservoir filler neck is removable from the master cylinder fluid reservoir. The filler neck if required, can be replaced as a separate component of the fluid reservoir. The filler neck is removed and installed using the following procedure. REMOVE 1. Check brake fluid level in master cylinder fluid reservoir to be sure brake fluid is not in the filler neck. If brake fluid is in filler neck, lower fluid level before removing filler neck from fluid reservoir Master Cylinder Fluid Reservoir Filler Neck 2. Grasp filler neck at cap end and push straight down. This will cause the filler neck to pop out of the fluid reservoir. INSTALL 1. Wet the O-ring on the reservoir end of the filler neck with fresh clean brake fluid. 2. Position the filler neck in the opening on the fluid reservoir. Ensure tab on filler neck is in the groove on the front of the fluid reservoir. 3. Push down while slightly rocking filler neck until filler neck snaps into the fluid reservoir opening. 4. Install cap on filler neck. 5. Check and/or add brake fluid in reservoir to ensure it is at the correct level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 5910 Brake Master Cylinder: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal 1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master cylinder push rod. Vacuum Seal Installed On Master Cylinder 4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When installing new vacuum seal, be sure it is squarely seated against master cylinder mounting flange and in groove of push rod. 5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6. Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to ensure proper operation of the vehicle's power brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Diameter 3/4 in To Support Plate Mounting Bolts 75 in.lb Bleeder Screw 80 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 5914 Rear Wheel Cylinder (Exploded View) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation REMOVE 1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid.) 2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel cylinder attaching bolts. Then pull wheel cylinder assembly off the brake support plate. INSTALL 1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5917 Wheel Cylinder: Service and Repair Cleaning and Inspection With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5918 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul Fig 3 Wheel Cylinder DISASSEMBLE To disassemble the wheel cylinders, proceed as follows: 1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston that remain in the wheel cylinder. 3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; (DO NOT USE ANY PETROLEUM BASE SOLVENTS) clean thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.) 4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLE Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the wheel cylinder cups with only Mopar Protect-A-Cup Lubricant p/n 04883068 and no substitute. 3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder. Be careful not to damage boot during installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Technical Service Bulletins > Rear Wheel Park Brake Actuator/Lever - Service Parking Brake Actuator: Technical Service Bulletins Rear Wheel Park Brake Actuator/Lever Service NUMBER: 05-09-99 GROUP: Brakes DATE: Nov. 5, 1999 SUBJECT: Rear Wheel Park Brake Actuator/Lever Service MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager 1997 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR WHEEL DISC BRAKES (SALES CODE BRE OR BR3). DISCUSSION: Whenever servicing the park brake actuator/lever of rear wheel disc brake equipped vehicles, DO NOT attempt to repair it. The park brake actuator/lever must be replaced with p/n 04882584AA whenever service is required. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Adjustments Parking Brake Cable: Adjustments The park brake cables on this vehicle have an automatic self adjuster built into the park brake pedal mechanism. When the foot operated park brake pedal is in its released (upward most) position, a clock spring automatically adjusts the park brake cables. The park brake cables are adjusted (tensioned) just enough to remove all the slack from the cables. The automatic adjuster system will not over adjust the cables causing rear brake drag. Due to the automatic adjust feature of the park brake pedal, adjustment of the parking brake cables on these vehicles relies on proper drum brake and park brake shoe adjustment. When the park brake pedal is applied the self adjuster is by-passed and the pedal operates normally to engage the park brakes. When a service procedure needs to be performed on the park brake pedal or the park brake cables, the automatic self adjuster can be manually locked out by the service technician. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement Parking Brake Cable: Service and Repair Front Cable Replacement REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lockout the automatic self adjusting mechanism of the park brake pedal assembly. See: Service and Repair Park Brake Cable Attachment To Equalizer 3. Remove the intermediate and left rear park brake cable from the park brake cable equalizer. Front Park Brake Cable Attachment To Body 4. Remove the front park cable housing retainer from body outrigger bracket. Cable is removable by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. 5. Lower vehicle. 6. Remove the left front door sill molding. 7. Remove the left front kick panel for access to the park brake cable and park brake pedal assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5929 Front Park Brake Cable At Floor Pan 8. Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable out of the floor pan of vehicle. 9. Pull park brake cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of pedal assembly bracket. 10. Remove cable retainer from the park brake pedal assembly bracket. 11. Pull park brake cable assembly out of vehicle through hole in floor pan. INSTALL 1. Pass park brake cable assembly through hole in floor pan from the inside of the vehicle. 2. Pass cable strand button through the hole in the pedal assembly bracket. 3. Install cable retainer onto the park brake cable and then install cable retainer into pedal assembly bracket. 4. Install the end of the park brake cable into the retainer previously installed into the park brake pedal bracket. 5. Install cable strand button into the clevis on the park brake pedal mechanism. 6. Install the front park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange on the seal is flush with the floor pan. Fold carpeting back down on floor. 7. Raise vehicle. 8. Insert brake cable and housing into body outrigger bracket making certain that housing retainer fingers lock the housing firmly into place. 9. Assemble the park brake cables onto the park brake cable equalizer. 10. Release the automatic adjuster mechanism on the park brake pedal assembly. Refer to Parking Brake Automatic Adjuster in the Service Procedures Section in this group of the service manual for the required procedure. 11. Lower vehicle and apply the park brake pedal 1 time, this will seat the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5930 Parking Brake Cable: Service and Repair Intermediate Cable Replacement REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lockout the automatic self adjusting mechanism of the park brake pedal assembly. See: Service and Repair Park Brake Cable Attachment To Equalizer 3. Remove the intermediate park brake cable from the park brake cable equalizer. Intermediate Cable Attachment To Right Rear Cable 4. Remove the intermediate park brake cable from the cable connector attaching it to the right rear park brake cable. 5. Remove the intermediate park brake cable from the cable guides on the frame rails. INSTALL 1. Install the ends of the park brake cables through the cable guides. 2. Install the intermediate park brake cable on the cable connector at the right rear park brake cable. 3. Install the intermediate park brake cable on the cable equalizer. 4. Remove the locking pliers from the front park brake cable. This will activate the automatic adjuster and correctly adjust the park brake cables. 5. Install and position the foam collar on the park brake cable to prevent it from rattling against floor. 6. Lower vehicle and apply the park brake pedal 1 time, this will seat the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5931 Parking Brake Cable: Service and Repair Left Rear Cable Replacement REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Locking Out Automatic Adjuster 4. Create slack in rear park brake cables by locking out the automatic adjuster as described. Grasp exposed section of front park brake cable and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket. Park Brake Cable Attachment To Equalizer 5. Disconnect the left rear park brake cable from the park brake cable equalizer. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5932 Park Brake Cable Removal From Body Bracket 6. To remove park brake cable housing from the body bracket, slide a 14 mm box end wrench over retainer end compressing the three fingers. Alternate method is to use an aircraft type hose clamp. 7. Remove the brake shoes from the brake support plate. 8. Disconnect park brake cable from park brake actuator lever. Removing Park Brake Cable From Brake Support Plate 9. Remove the park brake cable housing retainer from the brake support plate using a 14 mm wrench to compress the retaining fingers. INSTALL 1. Install the park brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the park brake cable onto the park brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect rear park brake cable to the equalizer bracket. 6. Install brake drum, and wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Apply and release park brake pedal 1 time, this will seat the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5933 Parking Brake Cable: Service and Repair Right Rear Cable Replacement REMOVE 1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Locking Out Automatic Adjuster 4. Create slack in the rear park brake cables by locking out the automatic adjuster as described. Grasp exposed section of front park brake cable and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket. Intermediate Cable Attachment To Right Rear Cable 5. Disconnect the right rear park brake cable from the connector on the intermediate cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Cable Replacement > Page 5934 Right Park Brake Cable Removal From Body Bracket 6. To remove the right park brake cable housing from the body bracket, slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers. The alternate method using an aircraft type hose clamp will not work on the right side of the vehicle. 7. Remove the brake shoes from the brake support plate. 8. Disconnect park brake cable from park brake actuator lever. Removing Park Brake Cable From Brake Support Plate 9. Remove the park brake cable housing retainer from the brake support plate using a 14 mm wrench to compress the retaining fingers. INSTALL 1. Install the park brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the park brake cable onto the park brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect the right rear park brake cable to the connector on the intermediate park brake cable. 6. Install the brake drum, and the wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Apply and release park brake pedal 1 time, this will seat the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications Parking Brake Pedal: Specifications TIGHTENING SPECIFICATIONS Mounting Bolts ..................................................................................................................................... ................................................ 28 Nm (21 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 5938 Parking Brake Pedal: Service and Repair REMOVE 1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 2. Remove sill scuff plate from left door sill. 3. Remove the left side kick panel. 4. Remove the steering column cover from the lower instrument panel. 5. Remove the reinforcement from the lower instrument panel. Locking Out Automatic Adjuster 6. Lock out front park brake cable using the following procedure. Grasp the exposed section of the front park brake cable and pull rearward on it. While holding the park brake in this position, install a pair of locking pliers on the front park brake cable just rearward of the second body outrigger bracket. 7. Remove the front park brake cable from the park brake cable equalizer. 8. Remove tension from front park brake cable. Tension is removed by releasing the locking pliers from the front park brake cable. 9. Remove the 3 bolts mounting the wiring junction block to the instrument panel. NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access the lower mounting bolt. 10. Remove the lower bolt mounting the park brake pedal to the body. 11. Remove the forward bolt mounting the park brake pedal to the body. 12. Remove the upper bolt mounting the park brake pedal to the body. Park Brake Pedal Mounting 13. Disconnect the electrical connector for the brake light switch. 14. Pull downward on front park brake cable while rotating park brake pedal mechanism out from behind junction block. 15. Remove park brake pedal release cable from park brake mechanism. 16. Remove the ground switch for the red brake warning lamp from the park brake pedal mechanism. 17. Remove front park brake cable button from park brake pedal mechanism. Tap end housing of front park brake cable out of park brake pedal mechanism. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Specifications > Page 5939 INSTALL 1. Install the ground switch for the red brake warning lamp on the park brake pedal mechanism 2. Install park brake cable end housing into park brake pedal mechanism. 3. Install cable retainer onto the park brake cable strand and then install retainer into pedal bracket. 4. Install cable strand button into the clevis on the park brake pedal mechanism. 5. Install wiring harness connector on red brake warning lamp ground switch. 6. Install the park brake release cable on the release mechanism of the park brake pedal. 7. Position the park brake pedal mechanism into its installed position on the body of the vehicle. 8. Remove the lock-out pin from the park brake pedal release mechanism. 9. Loosely install the top bolt mounting the park brake pedal mechanism to the body. 10. Loosely install the forward bolt mounting the park brake pedal mechanism to the body. 11. Loosely install the lower bolt mounting the park brake pedal mechanism to the body. 12. Tighten pedal mechanism attaching bolts to 28 Nm (250 inch lbs.). 13. Verify that the park brake pedal is in the fully released (full up) position. 14. Raise vehicle. 15. Install the front park brake cable on the park brake cable equalizer. 16. Lower vehicle. 17. Remove the lock-out pin from the automatic cable adjuster on the park brake pedal mechanism. 18. Install the electrical junction block on the instrument panel. 19. Install the reinforcement on the lower instrument panel. 20. Install the steering column cover on the lower instrument panel. 21. Install the left side kick panel. 22. Install the sill scuff plate on the lower sill of the left door. 23. Install the negative (ground) cable oil the battery. 24. Cycle the park brake pedal one time. This will seat the park brake cables and will allow the automatic self adjuster to properly tension the park brake cables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments PARK BRAKE SHOES (WITH REAR DISC BRAKES) CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. Disc Brake Caliper 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from hub/bearing. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. Measuring Park Brake Drum Diameter 5. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5943 Reading Park Brake Drum Diameter 6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool. Setting Gauge To Park Brake Shoe Measurement 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. Adjusting Park Brake Shoes 8. Place Gauge, Brake Shoe, Special Tool C-3919 or equivalent over the park brake shoes. The special tool must be located straight across at the center (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Install rotor on hub/bearing. 11. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 12. Install disc brake caliper on caliper adapter. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5944 13. Install wheel and tire. 14. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 15. Lower vehicle. 16. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 17. Road test the vehicle to ensure proper function of the vehicle's brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal Parking Brake Shoe: Service and Repair Removal NOTE: On this vehicle, the park brake shoes are removed from the disc brake adapter with the disc brake adapter removed from the vehicle. 1. Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from rotating when loosening the hub nut. 2. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. 3. Remove the wheel/tire. Cotter Pin And Nut Retainer 4. Remove the cotter pin and nut retainer from the stub shaft of the outer C/V joint. Spring Washer 5. Remove the spring washer from the stub shaft of the outer C/V joint. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5947 Hub Nut and Washer 6. Remove the hub nut and washer from the stub shaft of the outer C/V joint. 7. Release the parking brake. Locking Out Automatic Adjuster 8. Create slack in the rear park brake cables by locking the out the automatic adjuster as described. Grasp the exposed section of front park brake cable and pull downward on it. Then install a pair of locking pliers on the front park brake cable just rearward of the second body outrigger bracket. Removing Caliper Guide Pin Bolts 9. Remove the disc brake caliper to adapter guide pin bolts. Removing/Installing Caliper Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5948 10. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up from the adapter. Then pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter. Correctly Supported Caliper 11. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 12. Remove the rotor from the hub/bearing. Park Brake Cable Attachment To Actuator 13. Remove the horseshoe clip from the retainer on the end of the park brake cable. 14. Remove the end of the park brake cable from the actuator lever on the adapter. Park Brake Cable Removal From Adapter 15. Remove the end of the park brake cable from the adapter. Park brake cable is removed from adapter using a 1/2 wrench slipped over the park brake cable retainer as show to compress the locking tabs on the park brake cable retainer. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5949 Speed Sensor Attaching Bolt 16. Remove the attaching bolt from the wheel speed sensor. Then remove wheel speed sensor from hub/bearing and adapter. Hub/Bearing Mounting Bolts 17. Remove the hub/bearing to axle mounting bolts. Hub/Bearing Removal And Installation 18. Remove the hub/bearing from the axle and the stub shaft of the outer C/V joint. 19. Remove the adapter from the rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5950 Adapter Mounted In Vise 20. Mount the adapter in a vise using the anchor boss for the park brake cable. Lower Return Spring 21. Remove the lower return spring from the leading and trailing park brake shoes. Leading Brake Shoe Hold Down Pin And Spring 22. Remove the hold down spring and pin from the leading park brake shoe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5951 Brake Shoe Adjuster 23. Remove the adjuster from the leading and trailing park brake shoe. Primary Brake Shoe Remove/Install 24. Remove the leading park brake shoe from the adapter. Leading brake shoe is removed by rotating the bottom of the brake shoe inward until the top of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return springs from the leading brake shoe. Upper Return Springs 25. Remove the upper return springs from the trailing park brake shoe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5952 Trailing Brake Shoe Hold Down Pin And Spring 26. Remove the hold down spring and pin from the trailing park brake shoe. 27. Remove the trailing park brake shoe from the adapter. 28. Remove the park brake shoe actuator from the adapter and inspect for signs of abnormal wear and binding at the pivot point. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5953 Parking Brake Shoe: Service and Repair Installation 1. Install the trailing brake shoe on the adapter. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. Trailing Brake Shoe Hold Down Pin And Spring 2. Install the hold down spring and pin on the trailing park brake shoe. Upper Return Springs 3. Install the upper return springs on the trailing park brake shoe. Primary Brake Shoe Remove/Install Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5954 4. Install the upper return springs on the leading park brake shoe. Then position the top of the leading park brake shoe at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter. Brake Shoe Adjuster 5. Install the adjuster between the leading and trailing park brake shoe. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. Leading Brake Shoe Hold Down Pin And Spring 6. Install the hold down spring and pin on the leading park brake shoe. Lower Return Spring Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5955 7. Install the lower return spring on the leading and trailing park brake shoes. When installing the hold down spring it is to be installed behind the park brake shoes. 8. Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle. Adapter Installed On Mounting Bolts 9. Position the adapter on the 4 mounting bolts installed in the rear axle. Hub/Bearing Removal And Installation 10. Install the hub/bearing on the stub shaft of outer C/V joint and into the end of the axle. 11. In a progressive criss-cross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). Speed Sensor Attaching Bolt 12. Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor attaching bolt. Tighten the wheel speed sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5956 attaching bolt to a torque of 12 Nm (105 inch lbs.). 13. Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on the park brake cable retainer are expanded out to ensure the cable will not pull out of the adapter. Park Brake Cable Attachment To Actuator 14. Install the end of the park brake cable on the park brake actuator lever. NOTE: The horseshoe clip must be installed and installed properly when the park brake cable is installed in the adapter. The purpose of the horseshoe clip is to prevent park brake cable retainer from moving in the adapter. If horseshoe clip is not installed the park brake cable retainer will rattle in the adapter. 15. Install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip is installed between the retainer for the park brake cable and the adapter. Horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing toward the rear of the vehicle. Locking Out Automatic Adjuster 16. Remove the locking pliers from the front park brake cable. 17. Adjust the park brake drum-in-hat brake shoes. 18. Install the rotor on the hub/bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5957 Removing/Installing Caliper 19. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. Removing Caliper Guide Pin Bolts 20. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.). Hub Nut and Washer 21. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut on the stub shaft of the outer C/V joint. 22. Set the parking brake. 23. Tighten the hub nut to a torque of 244 Nm (180 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Removal > Page 5958 Spring Washer 24. Install the spring washer on the stub shaft of the outer C/V joint. Cotter Pin And Nut Retainer 25. Install the nut retainer and cotter pin on the stub shaft of the outer C/V joint. 26. Install the wheel and tire assembly. 27. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 28. Remove jackstands or lower hoist. 29. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 30. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications DIMENSIONS: Mounting Stud Size ............................................................................................................................. .............................................................. M8 x 1.25 Boost At 20 Inches Of Manifold Vacuum ........................................................................................................................................... 3800 Nm (850 lbs.) TIGHTENING TORQUES: To Dash Panel Mounting Nuts ........................................................................................................................................................ 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 5963 Vacuum Brake Booster: Description and Operation All vehicles use a 270 mm single diaphragm power brake vacuum booster. Power Brake Booster Identification The power brake booster can be identified if required, by the tag attached to the body of the booster assembly. This tag contains the following information: The production part number of the power booster assembly, the date it was built, and who was the manufacturer of the power brake vacuum booster. NOTE: The power brake booster assembly is not a repairable component and must be replaced as a complete assembly if it is found to be faulty in any way. The check valve located in the power brake booster is not repairable but it can be replaced as an assembly separate from the power brake booster. The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop vehicle. Power Brake Booster Assembly The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through the power brake booster check valve. As the brake pedal is depressed, the power brake boosters input rod moves forward. This opens and closes valves in the power booster, allowing atmospheric pressure to enter on one side of a diaphragm- Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the power booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. The different engine combinations used on this vehicle require that different vacuum hose routings to the power brake vacuum booster be used. All vacuum hoses must be routed from the engine to the power brake vacuum booster without kinks, excessively tight bends or potential for damage to the vacuum hose. The power brake vacuum booster assembly mounts on the engine side of the dash panel, and is connected to the brake pedal by the input push rod. A vacuum line connects the power booster to the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement Removal CAUTION: Reserve vacuum in the vacuum booster must be pumped down (removed) before removing master cylinder from vacuum booster. This is necessary to prevent the vacuum booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). 2. Remove both battery cables from battery. 3. Remove the battery thermal guard and the battery from the battery tray. Air Inlet Resonator 4. Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner housing. 5. If vehicle is equipped with speed control, unplug wiring harness connector from the speed control servo. Then disconnect vacuum lines from the speed control servo and vacuum reservoir on battery tray. 6. Remove bolt attaching the speed control servo bracket to the battery tray Slide the bracket forward to unhook it from the battery tray and remove. Battery Tray Mounting Locations 7. Remove the 2 bolts and the nut attaching the battery tray to the body of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5966 Electrical Connector At EGR Transducer 8. Remove the wiring harness connector from the EGR valve transducer. Electrical And Vacuum Connections To Throttle Body 9. Remove wiring harness connectors from throttle position sensor and AIS motor on throttle body. Throttle Body Attachment To Intake Manifold 10. Remove the 2 bolts attaching the throttle body to the intake manifold and the clip attaching the wiring harness to the throttle cable bracket. Then remove the throttle body and throttle cable bracket as an assembly from the intake manifold. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5967 Fluid Level Sensor Electrical Connection 11. Remove wiring harness connector from brake fluid level sensor in master cylinder fluid reservoir. 12. Clean the area where the master cylinder assembly attaches to the power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. Master Cylinder Attachment To Vacuum 13. Remove clip, attaching drain hose for wiper module to brake tube at master cylinder. Remove drain hose from wiper module. Remove the 2 nuts, attaching the master cylinder to the vacuum booster. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the vacuum booster. 14. Remove master cylinder and brake tubes as an assembly from the vacuum booster. When master cylinder is removed, lay it out of the way on top of the left motor mount. EGR Valve Attachment To Intake Manifold Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5968 15. Remove the EGR Valve and the vacuum transducer as an assembly from the intake manifold. 16. Disconnect vacuum hose from check valve located on vacuum booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER. Vacuum Booster Input Rod Retaining Pin 17. Locate the vacuum booster input rod to brake pedal connection under the instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip. 18. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. 19. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly. 20. From outside the vehicle, slide power brake vacuum booster forward until its mounting studs clear dash panel. Then tilt the booster up and toward the center of vehicle to remove. CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly. Installation CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle. 1. Position vacuum booster on dash panel using the reverse procedure of its removal. 2. Install the 4 nuts mounting the vacuum booster to the dash panel. Tighten the 4 mounting nuts to a torque of 29 Nm (250 inch lbs.). 3. Using Lubriplate, or an equivalent, coat the surface of the brake pedal pin where it contacts the vacuum booster input rod. CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do not re-use the old retaining clip. Retaining Pin Installed On Brake Pedal Pin 4. Install vacuum booster input rod on brake pedal pin and install a NEW retaining clip. 5. Connect the vacuum hose on the check valve in the power brake vacuum booster. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5969 EGR Valve Attachment To Intake Manifold 6. Install EGR Valve and vacuum transducer on the intake manifold. Install and tighten the 2 EGR valve mounting bolts to a torque of 22 Nm (200 inch lbs.). CAUTION: The master cylinder is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool. 7. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. Vacuum Seal Installed On Master Cylinder 8. Install a NEW vacuum seal on mounting flange of the master cylinder. 9. Position master cylinder on studs of vacuum booster, aligning push rod on vacuum booster with master cylinder piston. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5970 Master Cylinder Attachment To Vacuum 10. Install the 2 nuts mounting the master cylinder to the vacuum booster. Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). 11. Install the wiper module drain hose on the wiper module. Install the tie strap attaching the wiper module drain hose to brake tube at the master cylinder. Tie strap should be loosely tightened so as not to collapse the wiper module drain hose. Fluid Level Sensor Electrical Connection 12. Install the wiring harness connector on the brake fluid level sensor in the master cylinder fluid reservoir. Throttle Body Attachment To Intake Manifold 13. Install the throttle body and throttle cable bracket on the intake manifold. Install the 2 bolts attaching the throttle body to the intake manifold and tighten to a torque of 25 Nm (225 inch lbs.) Install clip attaching the wiring harness to the throttle cable bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5971 Electrical And Vacuum Connections To Throttle Body 14. Install the wiring harness connectors on the throttle position sensor and the AIS motor on throttle body. Electrical Connector At EGR Transducer 15. Install the wiring harness connector on the EGR valve transducer. Battery Tray Mounting Locations 16. Install the battery tray. Install the 2 bolts and the nut attaching the battery tray to the vehicle. Tighten the 2 bolts and the nut to a torque of 14 Nm (125 inch lbs.). 17. If vehicle is equipped with speed control, install the speed control servo and bracket on the battery tray. Install and securely tighten bolt attaching bracket to battery tray. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5972 18. If vehicle is equipped with speed control, install the wiring harness connector on the speed control servo. Then connect the vacuum lines onto the speed control servo and vacuum reservoir on battery tray. Air Inlet Resonator 19. Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing. Securely tighten hose clamp at air cleaner housing and throttle body. 20. Install the battery and the battery thermal guard. 21. Install the battery cables on the battery. 22. Check the operation of the stop lamp switch and adjust if necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Vacuum Booster Replacement > Page 5973 Vacuum Brake Booster: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal 1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master cylinder push rod. Vacuum Seal Installed On Master Cylinder 4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When installing new vacuum seal, be sure it is squarely seated against master cylinder mounting flange and in groove of push rod. 5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6. Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to ensure proper operation of the vehicle's power brake system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Description and Operation ABS Main Relay: Description and Operation ABS FUSES Fuse Locations In Power Distribution Center The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center (PDC). The PDC is located on the drivers side of the engine compartment forward of the strut tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the junction block. On vehicles equipped with traction control, the fuse for the traction control switch is also located in the junction block. The junction block is located on the left hand front cowl panel on the vehicle. ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will need to be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications To HCU Mounting Bolts ....................................................................................................................... .................................................. 2 Nm (17 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5981 Controller Antilock Brakes Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5982 Controller Antilock Brakes Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 5983 Electronic Brake Control Module: Description and Operation The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock Brake System (ABS) amber warning lamp. The primary functions of the CAB are to: - detect wheel locking tendencies - control fluid pressure modulation to the brakes during antilock stop - monitor the system for proper operation - provide communication to the DRB while in diagnostic mode - store diagnostic information in non-volatile memory The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB for proper operation If the CAB detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp. If the antilock function is disabled, the system will revert to standard base brake system operation. CAB Inputs Include The Following: - ABS Warning Lamp - Diagnostic Communication - Four Wheel Speed Sensors - Ignition Switch - Fused B+ - Stop Lamp Switch - Traction Control Switch CAB Outputs Include The Following: - ABS Warning Light Actuation - Voltage - Eight Valves - Ten Valves With Traction Control - Diagnostic Communication - Body Controller Communication - Traction Control Lamp Illumination Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal Electronic Brake Control Module: Service and Repair Removal 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control Unit (HCU). 3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector when disconnected. CAB 25 Way Connector Unlocking CAB 25 Way Connector 4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of the HCU. The 25 way connector is removed from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake tubes. 5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5986 Brake Tube Connections To HCU 6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. HCU To Suspension Cradle Mounting Bolts 7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember. 8. Remove HCU and the mounting bracket as a unit from the vehicle. HCU Mounting Bolts 9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the mounting bracket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5987 Pump Motor To CAB Wiring Harness 10. Unplug the pump motor wiring harness from the CAB. CAB Attaching Bolts 11. Remove the 4 bolts attaching the CAB to the valve block of the HCU. Remove/Install CAB 12. Remove the CAB from the valve block of the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5988 Electronic Brake Control Module: Service and Repair Installation Remove/Install CAB 1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit (HCU). CAB Attaching Bolts 2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). Pump Motor To CAB Wiring Harness 3. Plug the pump/motor wiring harness into the CAB. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5989 HCU Mounting Bolts 4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front suspension crossmember. HCU To Suspension Cradle Mounting Bolts 5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the HCU bracket to the crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Brake Tube Connections To HCU Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Removal > Page 5990 CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis brake tube locations. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the HCU mounting bracket. 6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown. Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in the connector. Unlocking CAB 25 Way Connector 7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. Brake Tube Routing Clips 8. Install the routing clips on the brake tubes. 9. Lower vehicle. 10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation Brake Fluid Level Sensor/Switch: Description and Operation A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp circuit. This switch does not disable the ABS system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5995 Brake Fluid Level Sensor/Switch: Service and Repair The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for replacement of the brake fluid level sensor. Fluid Level Sensor Electrical Connection 1. Remove wiring harness connector from brake fluid reservoir level sensor. Master Cylinder Brake Fluid Level Sensor 2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid reservoir. 5. Connect the vehicle wiring harness connector to the brake fluid level sensor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Harness Side > Page 6000 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 6001 Traction Control Switch: Testing and Inspection REMOVAL AND INSTALLATION Traction Control Switch Connector 1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading between pins. Refer to Switch Continuity Table. Switch Continuity Table Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Diagrams > Page 6002 Traction Control Switch: Service and Repair Over Steering Column Bezel REMOVAL 1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control switch to the bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications Wheel Speed Sensor: Electrical Specifications Resistance 900 - 1,300 ohms Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 6007 Wheel Speed Sensor: Mechanical Specifications Total Indicator Run Out Allowed 0.006 in Front Air Gap 0.014 - 0.059 in Rear Air Gap 0.020 - 0.054 in To Axle Or Steering Knuckle Mounting Bolt 105 in.lb Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 6010 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 6013 Wheel Speed Sensor: Diagrams Rear Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 6014 Wheel Speed Sensor: Description and Operation Front Wheel Speed Sensor Rear Wheel Speed Sensor (FWD) One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate hydraulic pressure via the HCU to prevent the wheel(s) from locking. The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable. The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on the rear driveshaft. The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear driveshaft outboard constant velocity joint. Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's wheels and tires must all be the same size and type to generate accurate signals. Variations in wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles to occur. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 6015 Wheel Speed Sensor: Testing and Inspection CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake System are different then those used on past models of this vehicle equipped with antilock brakes. Reduced braking performance will result if this part is used on earlier model vehicles and an accident could result. Do not use on pre-1998 model year vehicles. Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or broken teeth, this can cause erratic speed sensor signals. Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was made, determine cause and correct before replacing the wheel speed sensor. Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification. Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the speed sensor head and the tone wheel to ensure it is at specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. Front Speed Sensor Cable Channel Bracket 3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame rail. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector Speed Sensor Cable To Vehicle Wiring Harness 4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect speed sensor cable from vehicle wiring harness. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6018 Front Wheel Speed Sensor Attaching Bolt 5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free. Front Wheel Speed Sensor Cable Routing 7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front wheel speed sensor assembly from the vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut tower. CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the channel bracket. 2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4. Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link. 5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of the base and ABS brake systems. Rear REMOVE 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and wheel assembly from the vehicle. CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also inspect connectors for any signs of previous damage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6019 Rear Speed Sensor Cable Connection To Vehicle Wiring Harness 3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during removal of the speed sensor cable. Speed Sensor Cable Attachment To Brake Flex Hose 4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips. Right Rear Speed Sensor Cable Routing 5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the axle flange, the brake tube clip and the routing clip from the track bar bracket on the axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6020 Rear Speed Sensor Routing Brackets And Clips 6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed sensor cable from the routing clips on rear brake tube. CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the sensor from side to side until free. Rear Wheel Speed Sensor Attaching Bolt 7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not come loose, do not use pliers. Tap with screw driver and hammer. 8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed sensor assembly from vehicle. INSTALL CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in this section may result in contact with moving parts and/or over extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to installing the attaching bolt. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle. The rear wheel speed sensor cable should be routed under the rear brake tube. CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake flex hose if damaged during installation of the wheel speed sensor cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6021 5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket. CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the vehicle wiring harness, do not force the connectors together. If the connectors are forced together, damage to the connectors will occur. 7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into the body hole. 9. Install the tire and wheel assembly on vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6022 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly. 3. Remove rear brake drum from the hub/bearing assembly. Rear Wheel Speed Sensor 4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage to the speed sensor during removal and installation of the hub/bearing assembly. Rear Hub/Bearing Mounting Bolts 5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle. Removing Rear Hub/Bearing From Axle 6. Remove the hub/bearing assembly from the rear axle and brake support plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6023 Tone Wheel Removal From Hub/Bearing Assembly 7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage by the vise jaws. Mount the hub/bearing assembly in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone wheel from the hub/bearing assembly. INSTALL Installing Tone Wheel On Hub/Bearing Assembly 1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or equivalent. Position Driver, Special Tool 6908-1 or equivalent with undercut side facing up on top of the tone wheel. Correctly Installed Tone Wheel 2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3. Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts into hub/ bearing assembly. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6024 6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 8. Check the air gap between the face of the wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum allowable tolerance of 1.2 mm (0.047 inch). 9. Install the brake drum onto the rear hub/bearing assembly. 10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6039 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6045 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6046 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6047 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 6051 Connector Pin Identification Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6056 Engine Compartment Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6057 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Description and Operation Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Voltage Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator field source (+) circuit. The voltage range is 12.9 to 15.0 volts Rated Amps Nippondenso 90 A HS PN 4727220 .................................................................................................... ..................................................................... 86 amps Nippondenso 120 A HS PN 4727221 .................................................................................................. ..................................................................... 98 amps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 6067 Alternator: Mechanical Specifications Battery Hold Down Bolt ....................................................................................................................... ................................................ 14 N.m (125 in. lbs.) Generator Mounting Bolts .................................................................................................................... .................................................. 54 N.m (40 ft. lbs.) Generator B+ Terminal ........................................................................................................................ .................................................... 9 N.m (75 in. lbs.) Starter Mounting Bolts ....................................... ..................................................................................................................................... 54 N.m (40 ft. lbs.) Starter Solenoid Battery Nut ........................................................................................................ .......................................................... 10 N.m (90 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6068 Alternator: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6069 Alternator: Description and Operation SYSTEM OPERATION The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical system through the generator, battery, and ground terminals. Noise emitting from the generator may be caused by: Worn, loose or defective bearings - Loose or defective drive pulley - Incorrect, worn, damaged or misadjusted drive belt - Loose mounting bolts - Misaligned drive pulley - Defective stator or diode Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6070 Alternator: Service and Repair REMOVAL 1. Release hood latch and open hood. Removal/Installation Of Battery Cables 2. Disconnect battery negative cable. 3. Remove windshield wiper housing. 4. Remove accessory drive belt. Generator Mounting Bracket 5. Remove bolt holding top of generator mount bracket to engine air intake plenum. 6. Remove bolts holding outside of generator mount bracket to generator mount plate. 7. Remove bolt holding top of generator to mount bracket. 8. Remove generator mount bracket from vehicle. 9. Rotate generator toward rear dash panel. Wire Connectors 10. Disconnect the push-in field wire connector from back of generator. 11. Remove nut holding B+ wire terminal to back of generator. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6071 12. Separate B+ terminal from generator. Generator Pivot Bolt 13. Remove bolt holding bottom of generator to lower pivot bracket. Generator 14. Remove generator from vehicle. INSTALLATION 1. Place generator in position on vehicle. 2. Install bolt to hold bottom of generator to lower pivot bracket. 3. Place B+ terminal in position on generator. 4. Install nut to hold B+ wire terminal to back of generator. 5. Connect the push-in field wire connector into back of generator. 6. Rotate generator forward away from dash panel. 7. Place generator mount bracket in position on vehicle. 8. Install bolt to hold top of generator to mount bracket. 9. Install bolts to hold outside of generator mount bracket to generator mount plate. 10. Install bolt to hold top of generator mount bracket to engine air intake plenum. 11. Install accessory drive belt. 12. Install windshield wiper housing. 13. Connect battery negative cable. 14. Verify generator charge rate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation SYSTEM OPERATION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Operation: The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery Temperature Sensor for more information). It then compensates and regulates generator current output accordingly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair This article has been updated by technical service bulletin number 19-06-99 Dated Sep. 17, 1999. Note: This bulletin applies to vehicles equipped with an automatic transaxle. Ignition Switch Housing Service The ignition switch housing, p/n 04690523, is now available as a separate service part. This part eliminates the need to replace the complete steering column assembly if the service issue only relates to the ignition switch housing. The service procedure to replace the ignition switch housing is below. REMOVAL 1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 2. Remove the screws attaching the lower steering column cover to the instrument panel, then remove the cover from the lower instrument panel. 3. Remove the parking brake release cable from the parking brake release lever, then move the lower steering column cover out of the way. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6079 4. Remove the 10 bolts attaching the lower steering column cover liner to the instrument panel, then remove the lower steering column cover liner. 5. Remove the 3 screws attaching the upper and lower shrouds to the steering column, then separate and remove both shrouds. 6. Remove the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6080 7. Remove the 2 screws securing the steering column fixed shroud to the steering column, then remove the shroud. 8. Remove the two screws holding the metal cover in place below the shifter/ignition interlock linkage, then remove the cover. 9. Disconnect the shifter/ignition interlock link from the lever on the lock cylinder housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6081 10. Remove the key cylinder. To do this: - Turn the key placing the key cylinder in the ON position. - Depress and hold the retaining tab on the bottom of the lock cylinder housing. - Pull the key cylinder straight out of the lock cylinder housing. 11. Remove the vehicle wiring harness connector from the key cylinder halo lamp. 12. Remove the key cylinder halo lamp from the lock cylinder housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6082 13. Remove the ignition switch mounting screw. 14. Depress the two retaining tabs, then remove the ignition switch from the lock cylinder housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6083 15. Disconnect both tilt mechanism springs from their mounting posts on the tilt housing, then move them to the side out of the way. 16. While supporting the lock cylinder housing, remove both mounting screws securing the lock cylinder housing to the column. 17. Remove the lock cylinder housing from the bottom of the steering column. INSTALLATION 1. Install the lock cylinder housing in the bottom of the steering column lining up the mounting holes. 2. Install the self-tapping lock cylinder housing mounting screws through the top of the column into the housing. Tighten the two mounting screws to a torque of 11 Nm (100 inch lbs.). 3. Connect both tilt mechanism springs back onto their mounting posts making sure the spring hooks engage the grooves in the posts. 4. Ensure that the ignition switch and the actuator shaft in the lock cylinder housing are in the ON position. 5. Carefully install the ignition switch over the actuator shaft. The switch will snap over the retaining tabs on the housing. 6. Install the ignition switch mounting screw. 7. Install the key cylinder halo lamp on the lock cylinder housing. 8. Install the vehicle wiring harness connector onto the key cylinder halo lamp. 9. Install the key cylinder (with key in it turned to the ON position) by sliding it straight into the lock cylinder housing aligning the retaining tab on the key cylinder with the hole in the lock cylinder housing. 10. Turn the key to the OFF position and remove the key. 11. Connect the shifter/ignition interlock link to the lever on the lock cylinder housing by aligning the retaining tab on the lever with the ramp on the link, then pushing the two together. 12. Install the metal cover in place below the shifter/ignition interlock linkage using the two screws. CAUTION: After the completion of step 12 in the installation process, you must verify that the shift lever interlock functions properly. With ignition Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 6084 key removed from lock cylinder and brake pedal depressed, attempt to shift out of park. If the lever moves out of the park position you must repeat steps 11 and 12 of the installation procedure. 13. Install the steering column fixed shroud on the steering column using its 2 mounting screws. 14. Install the trim bezel on the instrument panel above the steering column. The trim bezel is mounted to the instrument panel using 2 screws (one on each side of the column) and retaining clips. 15. Install the lower steering column shroud on the steering column. Install and securely tighten the center screw attaching the lower shroud to the tilt head on the column. 16. Install the upper steering column shroud over the tilt head of the steering column snapping it into place on the lower shroud. Install and securely tighten the 2 remaining screws attaching the upper shroud to the lower shroud. 17. Install the steering column cover liner on the instrument panel below the steering column. Install and securely tighten the 10 bolts attaching the steering column cover liner to the instrument panel. 18. Install the parking brake pedal release cable on the parking brake release lever in the lower steering column cover. 19. Install the lower steering column trim cover on the instrument panel below the steering column. Install and securely the screws attaching the lower steering column cover to the instrument panel. 20. Connect the negative (ground) cable on the battery terminal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6094 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or Cannot Be Removed NUMBER: 23-23-00 GROUP: Body DATE: JUNE 30, 2000 SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager OVERVIEW: This bulletin involves performing one or any combination of the following procedures; cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition lock cylinder and/or replacing the ignition lock housing and switch assembly. SYMPTOM/CONDITION: 1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent. 2. Unable to remove the ignition key from the lock cylinder. PARTS REQUIRED: AR(1)04778115 Key AR(1)05003843AB Cylinder, Ignition Lock AR(1)04690523 Assembly, Ignition Switch and Lock Housing EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE) IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE) DIAGNOSIS/REPAIR PROCEDURE: DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM. SYMPTOM/CONDITION ONE 1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface. 2. Disconnect the negative battery cable. 3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If the key does turn make a new key. NOTE: USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY. 5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6100 8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT ATTEMPT TO DISASSEMBLE THE Lock CYLINDER. 9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit. 10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). 11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14. 14. Remove the ignition lock housing and ignition switch as an assembly using the procedure outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY. 15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). NOTE: PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN. 16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the start position and then the accessory position. 17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key into the lock cylinder. Attempt to rotate the key. 18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the repair is complete. SYMPTOM/CONDITION TWO 1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when it is brought up into the Park position. 2. If the shift lever does not seat fully up and away from the driver the column will not allow the key to be removed. 3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: P8 - New Part XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6101 Ignition Switch Lock Cylinder: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Steering Column Cover 2. Remove steering column cover retaining screws. Steering Column Shroud Screws 3. Remove screws holding steering column shrouds and remove lower shroud. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6102 Lock Cylinder Retaining Tab 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). Socket In Lock Cylinder Housing 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position. 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Transmission Range Sensor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 6106 Connector Pin Identification Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Power rating ........................................................................................................................................ ............................................................... 1.2 kilowatts Voltage ............................................................ ......................................................................................................................................................... 12 Volts Free Running Test: - Voltage .............................................................................................................................................. ............................................................. 11 Volts - Amperage Draw ................................................................................................................................ .............................................................. 73 Amp - Minimum Speed ................................................................................................................................ ........................................................... 3,401 rpm Solenoid closing Voltage ..................................................................................................................... .................................................................... 7.5 Volts Cranking Amperage Draw Test ....................... ........................................................................................................................................... 150 to 200 Amps NOTE: Engine should be up to operating temperature. Extremely heavy oil or tight engine will increase starter amperage draw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 6111 Starter Motor: Mechanical Specifications Starter Mounting Bolts ......................................................................................................................... ................................................... 54 N.m (40 ft. lbs.) Starter Solenoid Battery Nut ............................. ...................................................................................................................................... 10 N.m (90 in. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6112 Starter Motor: Application and ID No of fields = 4 No of Poles = 4 Brushes = 4 Drive = Conventional Gear Train Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6113 Starter Motor: Service and Repair REMOVAL 1. Release hood latch and open hood. Battery Negative Cable 2. Disconnect battery negative cable. 3. Hoist and support vehicle on safety stands. Wire Connectors 4. Remove nut holding B+ terminal to starter solenoid. 5. Disconnect solenoid connector from starter. Starter Bolts 6. Remove bolts holding starter to transaxle bell- housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6114 Starter 7. Remove starter from bellhousing. 8. Separate starter spacer from transaxle bellhousing. INSTALLATION 1. Place starter spacer in position on transaxle bellhousing, flange toward flywheel. 2. Place starter in position on bellhousing. 3. Install bolts to hold starter to transaxle bellhousing. 4. Connect solenoid connector into starter. 5. Install nut to hold B+ terminal to starter solenoid. 6. Lower vehicle. 7. Connect battery negative cable. 8. Verify starter operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6118 Engine Compartment Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6119 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Horn/Cigar Lighter/Power Outlet (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6145 Auxiliary Power Outlet: Service and Repair REMOVAL Outlet Base Removal 1. Look inside and note position of the retaining bosses. 2. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. Tool For Outlet Removal 3. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same. 4. Disconnect the base wires. 5. Set base aside. Remove light ring and disconnect wire. INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location 3. Push base into the bezel till it locks. 4. Install 12 Volt outlet cap and check operation of outlet or element. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Locations Diode: Locations Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Locations > Page 6149 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Locations > Page 6150 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Locations > Page 6151 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Locations > Page 6152 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 Power Distribution Center: Connector Views Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6191 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6192 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6193 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6194 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6195 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6196 Fuse: Locations Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6197 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6198 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6199 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6200 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block Fuse Block: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6205 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6206 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6207 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6208 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6209 Fuse Block: Diagrams Power Distribution Block Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6210 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6211 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6212 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6213 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6214 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 Multiple Junction Connector: Connector Views Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 Multiple Junction Connector: Electrical Diagrams Junction Block Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 Junction Block (Part 1 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 Junction Block (Part 2 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 Junction Block (Part 3 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 Junction Block (Part 4 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 Junction Block (Part 5 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 Junction Block (Part 6 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Junction Block (Part 7 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 Junction Block (Part 8 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 Junction Block (Part 9 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 Junction Block (Part 10 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 Junction Block (Part 11 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Junction Block (Part 12 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Junction Block (Part 13 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 Junction Block (Part 14 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 Junction Block (Part 15 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 Junction Block (Part 16 Of 16) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 6259 Multiple Junction Connector: Service and Repair Junction Block REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. Junction Block 3. Disconnect four, forty-way connectors from Junction Block. 4. Disconnect two wire connectors from bottom of Body Control Module. 5. Remove bolts holding Junction Block to dash panel mounting. 6. Remove Junction Block from mounting bracket. 7. Remove screws holding Body Control Module to Junction Block. 8. Slide Body Control Module downward to disconnect guide studs on Junction Block from BCM mounting bracket. 9. Separate Junction Block from Body Control Module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6272 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6273 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6274 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6275 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6276 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6277 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6278 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6279 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6280 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6281 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6287 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6288 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6289 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6290 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6291 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6292 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6293 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6294 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6295 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6296 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision Wiring Harness: Technical Service Bulletins Interior - Seat Heater Harness Location Revision NUMBER: 26-04-99G GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision > Page 6301 8N-4 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Auxiliary Power Outlet: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Auxiliary Power Outlet: Electrical Diagrams Horn/Cigar Lighter/Power Outlet (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Horn/Cigar Lighter/Power Outlet (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6327 Auxiliary Power Outlet: Service and Repair REMOVAL Outlet Base Removal 1. Look inside and note position of the retaining bosses. 2. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. Tool For Outlet Removal 3. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the same. 4. Disconnect the base wires. 5. Set base aside. Remove light ring and disconnect wire. INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location 3. Push base into the bezel till it locks. 4. Install 12 Volt outlet cap and check operation of outlet or element. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations Diode: Locations Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6331 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6332 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6333 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6334 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions Power Distribution Center: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Power Distribution Center: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Power Distribution Center: Connector Views Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center Fuse: Locations Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6373 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6374 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6375 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6376 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6377 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6378 Fuse: Locations Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6379 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6380 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6381 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power Distribution Center > Page 6382 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block Fuse Block: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6387 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6388 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6389 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6390 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6391 Fuse Block: Diagrams Power Distribution Block Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6392 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6393 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6394 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6395 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction Block > Page 6396 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions Multiple Junction Connector: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Multiple Junction Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Multiple Junction Connector: Connector Views Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Multiple Junction Connector: Electrical Diagrams Junction Block Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 Junction Block (Part 1 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Junction Block (Part 2 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 Junction Block (Part 3 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Junction Block (Part 4 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 Junction Block (Part 5 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Junction Block (Part 6 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Junction Block (Part 7 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Junction Block (Part 8 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 Junction Block (Part 9 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Junction Block (Part 10 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 Junction Block (Part 11 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 Junction Block (Part 12 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 Junction Block (Part 13 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 Junction Block (Part 14 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 Junction Block (Part 15 Of 16) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 Junction Block (Part 16 Of 16) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Page 6441 Multiple Junction Connector: Service and Repair Junction Block REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. Junction Block 3. Disconnect four, forty-way connectors from Junction Block. 4. Disconnect two wire connectors from bottom of Body Control Module. 5. Remove bolts holding Junction Block to dash panel mounting. 6. Remove Junction Block from mounting bracket. 7. Remove screws holding Body Control Module to Junction Block. 8. Slide Body Control Module downward to disconnect guide studs on Junction Block from BCM mounting bracket. 9. Separate Junction Block from Body Control Module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6454 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6455 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6456 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6457 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6458 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6459 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6460 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6461 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6462 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6463 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations ABS Fuses ABS Fuses Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block Relay Box: Diagrams Junction Block Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6469 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6470 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6471 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6472 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6473 Relay Box: Diagrams Power Distribution Center Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6474 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6475 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6476 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6477 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6478 Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision Wiring Harness: Technical Service Bulletins Interior - Seat Heater Harness Location Revision NUMBER: 26-04-99G GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision > Page 6483 8N-4 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 783.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 802.5 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 6489 Alignment: Specifications With Tire Sizes P205/75/R14 or P215/65/R15 FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 747.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 766.0 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using Alternative Fuels or Electric Engine > Page 6490 Alignment: Specifications With Tire Sizes P205/75/R15 or P215/65/R16 FRONT: Individual Camber [1] ........................................................................................................................... ..................................................... +0.05° ± 0.40° Camber Side to Side Difference Not to Exceed ................................................................................................................................... 0.00° - 0.50° MAX Individual Caster [2] .................................................................................................................... ............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ................................................................................................... ........................................................................ +0.05° ± 0.10° Total Toe ............................................ ........................................................................................................................................................ +0.10° ± 0.20° Side to Side Toe Differential ........................................................................................ ....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle .................... .............................................................................................................................................................. . 0.00° ± 2.50° Ride Height [7] ............................................................................................................. ................................................................... 753.5 mm ± 10.0 mm Ride Height Side to Side Differential ........................................................................................................................................... 0.0 mm 12.5 mm MAX REAR: Individual Camber ................................................................................................................................ ...................................................... +0.00° ± 0.25° Individual Toe Right/Left ....................................... ...................................................................................................................................... 0.00° ± 0.40° Total Toe [4, 6] .................................................................................................................................... ......................................................... 0.00° ± 0.40° Thrust Angle [4] ................................................... ........................................................................................................................................ 0.00° ± 0.30° Ride Height [5, 7] ................................................................................................................................. ........................................... 772.0 mm ± 10.0 mm Ride Height Side to Side Differential [5] ...................................................................................................................................... 0.0 mm 12.5 mm MAX [1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent. [2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [3]: Toe-In is positive. [4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for proper ride heights and damaged/worn out suspension components and replace as necessary. [5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are not adjustable. If found to be out of specification check for damaged and/or worn out suspension components and replace as necessary. [6]: Toe out when backed on alignment rack is toe in when driving. [7]: Measured at top of fender wheel opening. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6491 Alignment: Service Precautions CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle alignment specifications, by heating and or bending. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Front-End Alignment Alignment: Description and Operation Front-End Alignment GENERAL INFORMATION Wheel alignment is the proper adjustment of all the interrelated suspension angles affecting the running and steering of the front and rear wheels of the vehicle. The method of checking front and rear wheel alignment will vary depending on the type of equipment being used. The instructions furnished by the manufacturer of the equipment should always be followed. With the exception that the wheel alignment specifications recommended by Chrysler Corporation should always be used. DESCRIPTION There are six basic factors which are the foundation to front wheel alignment. These are vehicle height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors only toe-in is normally mechanically adjustable on this vehicle. Camber Adjustment - is allowed in the event that a vehicle is involved in an accident and after repairs are made meeting manufacturers tolerance specifications, the camber setting will not meet manufacturers specifications. If camber adjustment is required, refer to the following Service Camber Adjustment Procedure for the required steps to be followed. CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle alignment specifications, by heating and or bending. CHECKS AND ADJUSTMENTS Alignment checks and adjustments should be made in the following sequence: 1. Camber 2. Toe Camber - is the number of degrees the top of the wheel and tire assembly is tilted inboard or outboard from a true vertical line. Inboard tilt is negative camber. Outboard tilt is positive camber. Excessive camber is a tire wear factor: negative camber causes wear on the inside of the tires tread surface, while positive camber causes wear to the outside of the tires tread surface. Toe - is measured in degrees or inches and is the distance the front edges of the tires are closer (or farther apart) than the rear edges. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Front-End Alignment > Page 6494 Alignment: Description and Operation Rear Alignment adjustment is not required. The rear axle alignment settings are preset at the factory and therefore no alignment is necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 6495 Alignment: Testing and Inspection PRE-WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment factors. The following part inspection and the necessary corrections should be made to those parts which influence the steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be the same size and in good condition and have approximately the same wear. Note the type of tread wear which will aid in diagnosing, refer to Tires. 2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has the following areas inspected and or adjusted. Recommended tire pressures, full tank of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated alignment rack. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking Caster and Camber Alignment: Service and Repair Checking Caster and Camber NOTE: All alignment specifications are to be checked and adjusted with the vehicle at its correct ride height. GENERAL INFORMATION Front suspension Caster and Camber settings on this vehicle are determined at the time the vehicle is designed. This is done by determining the precise mounting location of the vehicle's suspension components throughout the design and assembly processes of the vehicle. This is called a Net Build vehicle and results in no normal requirement to adjustment the Caster and Camber after a vehicle is built or when servicing the suspension components. Thus Caster and Camber are not normally considered an adjustable specification when performing an alignment on this vehicle. Though Caster and Camber are not adjustable they should be checked during the alignment procedure to ensure they meet the manufacturers specifications. PROCEDURE If front camber does not meet the vehicle alignment specifications, it can be adjusted using a Mopar (R) Service Kit, or equivalent developed to allow for camber adjustment. If a vehicle's front camber does not meet required specifications, the vehicles suspension components should be inspected for any signs of damage or bending and the vehicle ride height should be checked to verify it is within required specification. This inspection must be done before using the Mopar (R) Service Kit for setting camber to the vehicle specification. CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating bending or by performing any other modification to the vehicle's front suspension components. 1. Correctly position the vehicle on the alignment rack. Then install all required alignment equipment on the vehicle, per the alignment equipment manufacturers specifications. NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an equal number of times. Induce jounce (rear first then front) by grasping center of bumper and jouncing each end of vehicle an equal number of times. Bumper should always be released when vehicle is at the bottom of the jounce cycle. 2. Correctly jounce vehicle and then read the vehicle's current front and rear alignment settings. Compare the vehicle's current alignment settings to the vehicle specifications for camber, caster and Toe-in. If front and rear camber readings are within required specifications proceed to Setting Front Toe for the Toe-in adjustment procedure if required. See: Front Alignment - If Camber readings are not within specifications refer to Setting Camber Adjustment and Cam Bolt Installation. See: Setting Camber Adjustment and Cam Bolt Installation Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 6498 Alignment: Service and Repair Front Alignment 1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center steering wheel and lock in place using a steering wheel clamp. CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe adjustment. 3. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate inner tie rods of steering gear to set front Toe to the preferred Toe specification. 4. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 5. Adjust steering gear to tie rod boots at tie rod. 6. Remove steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 6499 Alignment: Service and Repair Setting Camber Adjustment and Cam Bolt Installation 1. If the front camber readings obtained are not within the vehicle's specifications, use the following procedure and the Mopar (R) Clevis Bolt Service Kit, or equivalent to provide camber adjustment. The kit contains 2 flange bolts, 2 cam bolts, and 2 dog bone washers. These components of the service kit are necessary to assemble the strut to the steering knuckle, after modification of the strut clevis bracket. 2. Verify that the strut and steering knuckle are not bent or otherwise damaged. If either component is bent or show other signs of damage, replace required components and check the camber setting again. 3. If no component is bent or damaged, use the following procedure for modifying the strut clevis bracket and adjusting the camber setting. 4. Raise front of vehicle until tires are not supporting the weight of the vehicle. Then remove wheel and tire assembly from the location on the vehicle requiring the strut to be modified. CAUTIONS: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake flex hose when removed from the strut assembly. If necessary use a wire hanger to support the steering knuckle assembly or if required remove the brake flex hose from the caliper assembly. - The steering knuckle strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 5. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard. Separate the steering knuckle from the Strut clevis bracket and position steering knuckle so it is out of the way of the strut. CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the hole beyond the indentations on the sides of the strut clevis bracket. 6. Using an appropriate grinder and grinding wheel slot the bottom hole in both sides of the strut clevis bracket. When grinding slot do not go beyond the indentation area on the sides of the clevis bracket. CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog bone washers from the Mopar (R) Clevis Bolt Service Kit, or equivalent can be used to attach the steering knuckle to the strut after the mounting hole is slotted. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking Caster and Camber > Page 6500 7. Install the flanged bolt from the Mopar (R) Clevis Bolt Service Kit, or equivalent into the top clevis bracket to steering knuckle mounting hole. Install the cam bolt into the bottom clevis bracket to steering knuckle mounting hole. 8. Install the dog bone washer on the steering knuckle to strut clevis bracket attaching bolts. Then install the nuts from the original attaching bolts onto the replacement bolts from the service kit. Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber, while still allowing the steering knuckle to move in clevis bracket. 9. Lower vehicle until the full weight of the vehicle is supported by the vehicles' suspension. Then correctly jounce the front and rear of vehicle an equal amount of times. 10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket. When camber is correctly set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again jounce front and rear of vehicle an equal amount of times and verify front camber setting. 11. When vehicle is at correct camber setting torque both front strut to steering knuckle attaching bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4 turn after required torque is met. 12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the preferred specification setting. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud To Steering Knuckle Nut/Bolt ..................................................................................................................................... 136 Nm (100 ft. lbs.) Wheel Stop .............................................................................................................................. ................................................................. 95 Nm (70 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6505 Front Steering Knuckle: Service Precautions CAUTION: The front suspension knuckle is not a repairable component of the vehicles front suspension IT MUST BE REPLACED. If bent, broken or damaged in any way, do not attempt to straighten or repair the steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Page 6506 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment of the strut damper, steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has the front hub/bearing assembly mounted to it. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire assembly from the vehicle. 4. Remove the wave washer from the end of the stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut. 6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6509 7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle. 8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly. Do not allow the brake caliper assembly to hang by the brake flex hose. 9. Remove the brake rotor from the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6510 10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. Tie Rod End Removal From Steering Knuckle Arm 11. Remove the tie rod end from steering knuckle using Remover, Special Tool MB-991113, or equivalent. 12. Remove the front wheel speed sensor from the steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6511 13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt when assembling the steering knuckle to the ball joint , the pinch bolt must be installed from the rear facing the front on the vehicle. 14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle. 15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6512 16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the steering knuckle from the strut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6513 Front Steering Knuckle: Service and Repair Installation 1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to Transmission and Drivetrain. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. NOTE: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6514 4. Install a NEW steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.). 5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6515 6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment. 8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake caliper assembly attaching bolts to a torque of 35 Nm (30 ft. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6516 10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor attaching bolt to a torque of 7 Nm (60 inch lbs.). 11. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 203 Nm (150 ft. lbs.). 14. Install the spring wave washer on the end of the stub axle. 15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock as shown. 16. Set front Toe on vehicle to required specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6522 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6523 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6524 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Capacity ............................................................................................................................................... ....................................................... 0.81 L (1.7 pints) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 6527 Power Steering Fluid: Fluid Type Specifications The recommended lubricant is Mopar Power Steering Fluid. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Page 6528 Power Steering Fluid: Service and Repair WARNING: Fluid level should be checked with engine off to prevent injury from moving parts. CAUTION: Do not use automatic transmission fluid in the power steering system. Do not overfill the power steering system. Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD when fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). In all pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair REMOVE 1. Remove the filler cap prom remote power steering fluid reservoir. 2. Raise vehicle on jack stands or centered on a frame contact type hoist. 3. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 4. Lower vehicle. 5. Remove the fluid supply hose from the remote power steering fluid reservoir. 6. Remove the 2 mounting screws attaching the remote fluid reservoir to the inner fender. 7. Remove remote reservoir from inner fender. INSTALL 1. Install remote power steering fluid reservoir on inner fender, by first inserting tab on reservoir into hole in inner fender. Then rotate reservoir so mounting tabs are against inner fender. 2. Install and securely tighten the 2 reservoir mounting screws. Power Steering Fluid Hose Routing Clip CAUTION: The reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This will prevent the hose from coming in contact with the accessory drive belt. 3. Install the fluid supply hose onto the power steering fluid reservoir fitting. Install the hose clamp on the fluid supply hose at the fluid reservoir. Be sure hose clamp is installed past bead on fluid reservoir fitting. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose at the power steering pump. Be sure hose clamp is installed past bead on pump flitting. 6. Lower vehicle. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair > Page 6532 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6541 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6542 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6543 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6544 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6545 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6546 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed Technical Service Bulletin # 19-11-97 Date: 971205 Power Steering Line - Honk Noise At Low Speed NO: 19-11-97 GROUP: Steering EFFECTIVE DATE: Dec. 5, 1997 SUBJECT: "Honk" Noise During Parking Lot Maneuvers FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE BULLETIN 19-07-97. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. DIAGNOSIS: The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise can be reproduced during the diagnostic procedure. The noise may decrease in severity or disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings, replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic procedure is performed, will temporarily eliminate the noise for approximately 200 miles. Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering wheel back toward the right, repeat several times. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011 873AA Line, Power Steering Return AR 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-17-90 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing revised power steering pressure and return lines. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6551 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1. 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear, Figure 2. Discard the line and screw clamp. 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting, Figure 3. 9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2. Remove and discard the power steering pressure line. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6552 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line, Figure 4. 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line on to the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in. lbs.) Figure 2. 18. POWER STEERING FLUID LEVEL ADJUSTMENT NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6553 h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. 19. Verify correct steering operation and no fluid leaks. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6559 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6560 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6561 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6562 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6563 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6564 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed Technical Service Bulletin # 19-11-97 Date: 971205 Power Steering Line - Honk Noise At Low Speed NO: 19-11-97 GROUP: Steering EFFECTIVE DATE: Dec. 5, 1997 SUBJECT: "Honk" Noise During Parking Lot Maneuvers FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE BULLETIN 19-07-97. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. DIAGNOSIS: The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise can be reproduced during the diagnostic procedure. The noise may decrease in severity or disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings, replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic procedure is performed, will temporarily eliminate the noise for approximately 200 miles. Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering wheel back toward the right, repeat several times. If the noise is heard, perform the Repair Procedure. PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011 873AA Line, Power Steering Return AR 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-50-17-90 0.4 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves installing revised power steering pressure and return lines. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6569 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1. 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear, Figure 2. Discard the line and screw clamp. 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting, Figure 3. 9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2. Remove and discard the power steering pressure line. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6570 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line, Figure 4. 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line on to the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in. lbs.) Figure 2. 18. POWER STEERING FLUID LEVEL ADJUSTMENT NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6571 h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. 19. Verify correct steering operation and no fluid leaks. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 6572 Power Steering Line/Hose: Specifications Hose Tube Nuts ................................................................................................................................... ..................................................... 34 Nm (25 ft. lbs.) Routing Bracket To Suspension Cradle .................................................................................................................................................... 28 Nm (21 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump REMOVE 1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. Power Steering Fluid Hose Routing Clip 3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the power steering fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain out of the reservoir and hose. 6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle. Hose is removed from the top of the engine compartment. INSTALL CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube. This routing will prevent the power steering fluid supply hose from coming in contact with the accessory drive belt. 1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on fluid reservoir fitting. 3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed past bead on pump fitting. 5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is installed in a position to correctly align with stud in strut tower. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper let and let the fluid settle for at least two (2) minutes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6575 9. Start the engine and let run for a few seconds. Then turn the engine off. 10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6576 Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if engine has been running. CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel tube connection. Remove the hose clamp from the power steering fluid return hose. Remove power steering fluid return hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid pressure line from the power steering pump pressure fitting. Drain excess power steering fluid from hose. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6577 6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle. 7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid pressure hose. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power steering pressure hose to the fittings on the power steering pump and steering gear. Route hose avoiding tight bends or kinking. Do not bend tube ends of the power steering hoses when installing. 4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle. CAUTION: When tightening and torquing the pressure hose at the power steering pump, the pressure hose is to be rotated against the fluid return hose fitting on the pump. 5. Tighten all fasteners shown for specific applications to their correct torques listed below: - Pump End Tube Nut: 34 Nm (25 ft. lbs.) - Gear End Tube Nut: 34 Nm (25 ft. lbs.) - Pump Bracket Nut: 40 Nm (30 ft. lbs.) 6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 7. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6578 CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. 8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 9. After hoses are installed and power steering system is filled with fluid and cap is installed on reservoir. Start the engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6579 Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if engine has been running. CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses, power steering pump fittings and steering gear ports to prevent entry of foreign material into the components. REMOVE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber hose from steel tube and allow power steering fluid to drain from pump. 5. Remove the power steering fluid return hose from the power steering pump return hose fitting. INSTALL 1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route hose smoothly avoiding tight bends or kinking. Hose must remain away from the exhaust system and not come in contact with any unfriendly surfaces of the vehicle. 3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is to prevent overheating of the power steering fluid hoses. 5. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 6. After hoses are installed and power steering system is filled with fluid and caps installed on reservoir. Start the engine and check for leaks. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage NUMBER: 19-005-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Power Steering Fluid Usage MODELS: 1993 - 2003 (AB) Ram Van 1994 - 2004 (AN) Dakota 1994 - 2002 (BR/BE) Ram Pickup 2004 (CS) Pacifica 1998-2004 (DN) Durango 2002 - 2004 (DR) Ram Pickup 1996 - 2000 (GS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2004 (KJ) Liberty 2002 - 2004 (KJ) Cherokee (International Markets) 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Voyager/Caravan 2002 (PG) Chrysler PT Cruiser (International Markets) 1995-2004 (PL) Neon 1997 - 2003 (PR) Prowler 2002 - 2004 (PT) Chrysler PT Cruiser 2001 - 2004 (RG) Chrysler Voyager (International Markets) 2001 - 2004 (RS) Town & Country/Caravan/Voyager 1993 - 2002 (SR) Viper/Viper Coupe 2001 - 2004 (ST) Sebring Coupe/Stratus Coupe 1997 - 2004 (TJ) Wrangler 2003 - 2004 (VA) Sprinter 1999 - 2004 (WG) Grand Cherokee (International Markets) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6584 1999-2004 (WJ) Grand Cherokee 2003 - 2004 (ZB) Viper 2004 (ZH) Crossfire DISCUSSION: The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4 (MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is no longer an indication of fluid condition. The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA. MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On some past models, MS9602 should be used as the replacement fluid. On these models, if a power steering system is being serviced that results in a large fluid loss, such as a pump, hose or gear/rack replacement, the complete system should be drained and filled with MS9602. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6585 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6586 NOTE: This bulletin supersedes owner's and service manuals for the vehicles listed above that may state to use MS9933 in the power steering system, and that may state not to use automatic transmission fluid in the power steering system. POLICY: Information Only. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications Flow Control Valve Fitting .................................................................................................................... ................................................... 75 Nm (55 ft. lbs.) Mounting Bolts ................................................... ...................................................................................................................................... 54 Nm (40 ft. lbs.) Rear Bracket To Engine Mounting Bolts .................................................................................................................................................. 54 Nm (40 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 6589 Power Steering Pump: Pressure, Vacuum and Temperature Specifications Flow at 1500 RPM & Min. Pressure ............................................................................................................................ 5.0 - 7.0 Liters/Min (1.3 - 1.9 GPM) Control Valve Pressure Relief ....................................................................................................................................... 9653 - 10342 kPa (1400 - 1500 psi) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6590 Power Steering Pump: Description and Operation Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power steering pump. The power steering pump is a constant flow rate and displacement vane type pump. The power steering pump used on all applications is the Vane-Submerged remote reservoir style power steering pump. The remote reservoir type pump has the pump housing and internal components combined with the fluid housing. But it has a remote reservoir for the power steering fluid supply. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal Replacement WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. DISASSEMBLE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection. Remove hose clamp from power steering fluid return hose. Remove power steering return hose from steel tube and allow remaining power steering fluid to drain from power steering pump and reservoir. 5. Remove the power steering fluid pressure line from the power steering pump pressure fitting. Drain excess power steering fluid from hose. 6. Remove the pressure fitting/flow control valve from the power steering pump and remove and discard the O-Ring seal. ASSEMBLE 1. Install a new O-Ring seal on the pressure fitting/flow control valve, and wet the O-Ring with clean fresh power steering fluid. 2. Install the pressure fitting/flow control valve in the power steering pump. Tighten the pressure fitting/flow control valve to a torque of 75 Nm (55 ft. lbs.). CAUTION: When tightening and torquing the pressure hose at the power steering pump, the hose should be rotated against the fluid return hose fitting on the pump. 3. Install the power steering fluid pressure hose in the pressure fitting/flow control valve. Tighten the tube nut to a torque of 34 Nm (25 ft. lbs.). 4. Install the power steering fluid return hose on the steel tube at the front suspension cradle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6593 5. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is required to keep the power steering hoses from becoming overheated. 6. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 7. Fill the power steering system with fluid, bleed air from system and check that power steering fluid is at correct level. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6594 Power Steering Pump: Service and Repair Power Steering Pump Initial Operation WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Use only Mopar Power Steering Fluid. Do not use automatic transmission fluid. Do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the fluid is at normal temperature of approximately 21° C to 27°C (70°F to 80°F). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6595 Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement REMOVE 1. Remove the pulley from the shaft of the power steering pump using Puller C-4333 or C-4068, or equivalent. CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the power steering pump. 2. Replace pulley if it is found to be bent, cracked, or loose. INSTALL 1. Install the pulley with Installer C-4063, or equivalent. Do not use the tool adapters. 2. Ensure that the tool and the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked on the shaft. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6596 3. Force pulley flush with the end of the power steering rums shaft. 4. With serpentine belts, run engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6597 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation Installation 1. Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel of the vehicle. 2. Install the power steering pump on its mounting bracket. Install the 3 power steering pump mounting bolts. Tighten the power steering pump mounting bolts to a torque of 54 Nm (40 ft. lbs.). 3. Install the support bracket attaching rear of power steering pump to engine. Tighten the nut and bolt holding the strut assembly to bracket and the intake manifold stud to a torque of 54 Nm (40 ft. lbs.). NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring on the power steering pressure hose for damage and replace if required. 4. Install the power steering fluid pressure line onto the output fitting of the power steering pump. Tighten the pressure line to pump fitting tube nut to a torque of 31 Nm (275 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6598 5. Install the power steering fluid, low pressure return hose on the power steering pump low pressure fitting. Be sure hose clamps are properly reinstalled. 6. Install the power steering fluid supply hose from the power steering fluid reservoir, on the power steering pump fluid fitting. Be sure hose is clear of accessory drive belts and all hose clamps are properly reinstalled. 7. Install the serpentine drive belt. Refer to Engine. 8. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 9. Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamps are properly reinstalled. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering fluid pressure and return hoses. This is required to keep the power steering hoses from becoming overheated. 10. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 11. Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on the exhaust system brackets. 12. Connect the oxygen sensor wiring harness to the vehicle wiring harness. Install wiring harness grommet in the floor pan of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6599 13. Install the accessory drive splash shield. 14. Lower vehicle. CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar, Power Steering Fluid, or equivalent. 15. Fill the remote power steering pump fluid reservoir to correct fluid level. 16. Install cap on power steering fluid reservoir. 17. Connect the negative battery cable on the negative battery post. 18. Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in system. Stop engine, check fluid level, and inspect system for leaks. Removal WARNING: Power steering oil, engine components and the exhaust system may be extremely hot if engine has been running. CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or catalyst. 1. Remove the (-) negative battery cable from the battery and isolate cable. 2. Remove cap from power steering fluid reservoir. 3. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Disconnect the oxygen sensor wiring harness from the vehicle wiring harness. Access to connection at vehicle wiring harness is through the oxygen sensor wiring harness grommet in the floor pan of the vehicle. NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle. 6. Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system hangers/isolators from the brackets on the exhaust system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6600 7. Move the exhaust system as far rearward and to the left side of the vehicle as possible. 8. Raise the heat sleeve on the power steering hoses to expose the hose to steel tube connection. Remove the hose from the power steering fluid return line on the front suspension cradle. Allow the remaining power steering fluid to drain from the pump and fluid reservoir through the removed return hose. 9. Remove the accessory drive splash shield. 10. Remove the serpentine accessory drive belt from the engine. Refer to Engine. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6601 11. Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the fitting on the power steering pump. Drain off excess power steering fluid from hose. 12. Remove the power steering fluid pressure line from the power steering pump. Drain excess power steering fluid from tube. 13. Remove the power steering fluid return hose from the power steering pump. Drain excess power steering fluid from tube. 14. Remove the support bracket at the rear of the power steering pump attaching the pump to the rear of the engine. 15. Remove the 3 bolts mounting the power steering pump to the alternator/power steering pump and belt tensioner mounting bracket. 16. Remove the power steering pump from its mounting bracket. 17. The power steering pump is removed from the vehicle by pulling it out through the exhaust tunnel area in the floor pan of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 6604 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 6605 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 6612 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair Steering Column Cover: Service and Repair REMOVAL Park Brake Release Handle 1. Remove screws holding parking brake release handle to instrument panel. Lower Steering Column Cover 2. Remove screws holding bottom of lower steering column cover to instrument panel. 3. Remove screw holding right side of lower steering column cover to instrument panel. Park Brake Release Handle Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Page 6616 4. Disengage park brake release cable case from groove on end of release handle. 5. Disengage cable end pivot from slot on release handle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area Technical Service Bulletin # 19-003-03 Date: 030829 Steering Column - Pop/Tick From Steering Wheel Area NUMBER: 19-003-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE CORRECTING VEHICLE BUILD DATES. SUBJECT: Pop/Tick Sound In Steering Wheel Area OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in the steering column upper tilt head. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) 1999 - 2002 (WJ) Grand Cherokee 2001 - 2002 (WG) Grand Cherokee (International Markets) NOTE: **This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before Jan. 13, 2002 (MDH 0113XX).** NOTE: **For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7, 2003.** SYMPTOM/CONDITION: A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion. The sound is associated with input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as driving over an expansion strip. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure. NOTE: If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99 (Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this bulletin. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6625 PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure 1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before beginning steering wheel removal procedure. WARNING: Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. 2. Remove and isolate the negative battery cable from the battery. 3. Remove the lower and upper steering column shrouds. 4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 5. Remove the steering wheel attaching nut. 6. Using the appropriate steering wheel puller, remove the steering wheel. 7. Remove the multi-function switch and its wiring connections. 8. Disconnect the clock spring wiring connection and remove the clock spring. NOTE: When removing the clock spring, do not change the orientation of the clock spring inner wheel. If the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered. Follow the procedure for clock spring centering in the appropriate service manual. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6626 9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly. 10. Remove the snap ring from the steering shaft upper tilt head assembly. 11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing. 12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column. 13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering column. 14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing wedge. 15. Remove and discard the wave washer. 16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing wedge (Fig. 1). 17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.). 18. Install the upper bearing wedge to the tilt steering shaft. 19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring groove. This will facilitate snap ring installation. 20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the steering shaft outward and push the snap ring as far down the shaft as possible. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6627 21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering shaft so the one edge of the tool is resting on the snap ring (Fig. 2). 22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool 05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into its groove on the steering shaft. NOTE: Do not over torque steering wheel nut. NOTE: Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool 05083385AA can be discarded. 23. Make sure that the snap ring is fully seated into its groove. 24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.). 25. Install the clock spring and its wiring connections. 26. Install the multi-function switch and its wiring connections. 27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.). 28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.). 30. Install the lower and upper steering column shrouds. 31. Connect negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area Technical Service Bulletin # 19-003-03 Date: 030829 Steering Column - Pop/Tick From Steering Wheel Area NUMBER: 19-003-03 GROUP: Steering DATE: Aug. 29, 2003 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE CORRECTING VEHICLE BUILD DATES. SUBJECT: Pop/Tick Sound In Steering Wheel Area OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in the steering column upper tilt head. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 2001 - 2002 (RG) Chrysler Voyager (International Markets) 1999 - 2002 (WJ) Grand Cherokee 2001 - 2002 (WG) Grand Cherokee (International Markets) NOTE: **This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before Jan. 13, 2002 (MDH 0113XX).** NOTE: **For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7, 2003.** SYMPTOM/CONDITION: A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion. The sound is associated with input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as driving over an expansion strip. DIAGNOSIS: If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure. NOTE: If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99 (Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this bulletin. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6633 PARTS REQUIRED: EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Repair Procedure 1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before beginning steering wheel removal procedure. WARNING: Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. 2. Remove and isolate the negative battery cable from the battery. 3. Remove the lower and upper steering column shrouds. 4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 5. Remove the steering wheel attaching nut. 6. Using the appropriate steering wheel puller, remove the steering wheel. 7. Remove the multi-function switch and its wiring connections. 8. Disconnect the clock spring wiring connection and remove the clock spring. NOTE: When removing the clock spring, do not change the orientation of the clock spring inner wheel. If the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered. Follow the procedure for clock spring centering in the appropriate service manual. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6634 9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly. 10. Remove the snap ring from the steering shaft upper tilt head assembly. 11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing. 12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column. 13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering column. 14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing wedge. 15. Remove and discard the wave washer. 16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing wedge (Fig. 1). 17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.). 18. Install the upper bearing wedge to the tilt steering shaft. 19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring groove. This will facilitate snap ring installation. 20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the steering shaft outward and push the snap ring as far down the shaft as possible. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering Column - Pop/Tick From Steering Wheel Area > Page 6635 21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering shaft so the one edge of the tool is resting on the snap ring (Fig. 2). 22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool 05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into its groove on the steering shaft. NOTE: Do not over torque steering wheel nut. NOTE: Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool 05083385AA can be discarded. 23. Make sure that the snap ring is fully seated into its groove. 24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.). 25. Install the clock spring and its wiring connections. 26. Install the multi-function switch and its wiring connections. 27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.). 28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring connections. 29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.). 30. Install the lower and upper steering column shrouds. 31. Connect negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6644 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6645 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6646 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6647 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6648 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6649 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed Technical Service Bulletin # 19-05-98 Date: 980828 Power Steering - Honk Or Squeal Noise at Low Speed NO: 19-05-98 GROUP: Steering DATE: Aug. 28, 1998 SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9, 1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES. SYMPTOM/CONDITION: **SYMPTOM ONE: "Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than one second. The noise usually occurs near the ends of steering travel when reversing direction. This noise condition typically does not develop until the vehicle has accumulated at least a few hundred miles. SYMPTOM TWO: A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering wheel to center from near the end of travel. This condition can occur on a new vehicle or one with little or no mileage after service. Two other potential steering system issues which are not covered under this bulletin are steering moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the entire steering range and usually related to power steering line grounding, air in the steering system due to leaks, or power steering pump performance. It may or may not be present at all temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary steering and may also be temperature dependent. Vehicles should be expected to have increased shudder after servicing the steering system. Several hundred customer miles may be required to stabilize the system. ** DIAGNOSIS: **If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair Procedure. Limited steering evaluations by service technicians to familiarize themselves with the issue should be performed, but prolonged evaluation of the steering system could result in overheating of the system resulting in incorrect diagnosis and system damage.** PARTS REQUIRED: 1 05011872AA Line, Power Steering Pressure 1 05011873AA Line, Power Steering Return 1 04883077 Fluid, Power Steering 2 04546098 Clip, Line 1 04641780 Strap, Tie 1 06035824 Clamp, Hose AR (1) 04874878AB Gear, Power Steering AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching AR (1) 06032839 Clamp POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6655 19-50-17-90 P/S Hose Replacement 0.4 Hrs. 19-00-02-92 Steering Gear Replacement 2.3 Hrs. FAILURE CODE: P8 - New Part Repair Procedure NOTE: THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN USED TO HIGHLIGHTS REVISIONS. This bulletin involves installing revised power steering pressure and return lines and/or power steering gear. WARNING: POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. NOTE: IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR REPLACEMENT PROCEDURE IN THIS BULLETIN. 1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap. 2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir. 3. Raise the vehicle on an appropriate hoist. 4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1). 5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan. 6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse. 7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear (Figure 2). Discard the line and screw clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6656 8. Remove the power steering fluid pressure line from the power steering pump pressure fitting (Figure 3). 9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2). Remove and discard the power steering pressure line. 10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear. NOTE: DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE. 11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump. 12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in. lbs.). 13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line (Figure 4). 14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line onto the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.). 15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components. 16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.) 17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm (240-310 in. lbs.). 18. POWER STEERING FLUID LEVEL ADJUSTMENT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6657 NOTE: DO NOT USE AUTOMATIC TRANSMISSION FLUID. a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes. b. Start the engine and let it run for 10 seconds and turn it off. c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes. d. Raise the front wheels off the ground. e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops. f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock. h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary. i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h. NOTE: STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE. 19. After performing the power steering fluid level adjustment procedure and verifying no system leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50 times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise occurs, replace the steering gear using the following procedure: Steering Gear Replacement Procedure 1. With the front wheels centered, turn the ignition switch to the locked position and remove the key from the switch. Turn the steering wheel to the left until the steering wheel security lock engages (180°). This step ensures the clock spring will not be over extended. 2. With the vehicle on the ground, remove the black trim cover at the lower left side of the instrument panel to gain access to the steering column shaft coupler. Disconnect the steering column shaft coupler from the steering gear intermediate coupler (Figure 5). 3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6658 4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then dispose of the fluid properly. 5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for the other side. 6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or MB-991113 (Figure 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6659 7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU. 8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Separate the cradle plate from the vehicle. 9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10). 10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and lower the steering gear enough to allow access to the intermediate coupler roll pin. 11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out of the intermediate coupler. Remove the special tool from the intermediate coupler. 12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear from the vehicle. 13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room to install the intermediate coupler. 14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then install the intermediate coupler onto the shaft of the steering gear. 15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the intermediate coupler. Remove the special tool from the intermediate coupler. 16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10. Torque the bolts/nuts to 183 Nm (135 ft. lbs.). 17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S fluid line tube nuts to 31 Nm (275 in.lbs.). 18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side. 19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8. Torque the bolts/nuts to 165 Nm (123 ft. lbs.). 20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6660 21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.). 22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still off the ground. 23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned with the steering column coupler and assemble the couplers together. 24. Lower the vehicle so its full weight is resting on the ground. 25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them to 28 Nm (250 in. lbs.). Install the safety pin. 26. P/S fluid level adjustment, use the procedure outline, step 18. 27. FRONT TOE IN ADJUSTMENT a. Ensure all tires are the same size and inflated to the recommended pressure. b. Verify vehicle ride height is within specification (Figure 12). c. Ensure the fuel tank is full and the vehicle is on a level surface d. Center the steering wheel and lock in place with a steering wheel clamp. NOTE: DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING FRONT WHEEL TOE IN ADJUSTMENT. e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°. f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.). g. Adjust the steering gear tie rod boots so they are not stressed. h. Remove the steering wheel clamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions Steering Gear: All Technical Service Bulletins Steering - Steering Gear R & I Revisions NUMBER: 26-08-98 GROUP: Miscellaneous DATE: August, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Caravan/Voyager/Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revision to the steering gear removal and Installation procedures Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6665 19-29 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6666 19-30 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6667 19-31 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions Steering Gear: All Technical Service Bulletins Steering - Steering Gear R & I Revisions NUMBER: 26-08-98 GROUP: Miscellaneous DATE: August, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Caravan/Voyager/Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revision to the steering gear removal and Installation procedures Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6673 19-29 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6674 19-30 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I Revisions > Page 6675 19-31 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 6676 Steering Gear: Specifications To Cradle Attaching Bolts .................................................................................................................... ................................................ 183 Nm (135 ft. lbs.) Coupler Pinch Bolt ............................................ .................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 6677 Steering Gear: Description and Operation NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear should be replaced. If a steering gear boot needs to be replaced due to damage, refer to Tie Rod Boot for proper procedure. The power steering system consists of these four major components. Power Steering Gear, Power Steering Pump, Pressure Hose, and Return Line. Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist steering is provided by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston, which, in turn, builds up hydraulic pressure and assists in the turning effort. The drive tangs on the pinion mate loosely with a stub shaft to permit manual steering control to be maintained if the drive belt on the power steering pump should break. However, under these conditions, steering effort will be increased. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 6678 Steering Gear: Testing and Inspection GENERAL INFORMATION The following procedure can be used to test the operation of the power steering system on this vehicle. This test will provide the flow rate for the power steering system along with the maximum relief pressure of the power steering pump. This test is to be performed any time a power steering system problem is present to determine if the power steering pump or power steering gear is not functioning properly. The following pressure and flow test is performed using Pressure/Flow Tester, Special Tool 6815, or equivalent. FLOW AND PRESSURE TEST PROCEDURE 1. Check power steering pump drive belt tension and adjust as necessary. 2. Disconnect power steering fluid pressure hose, at power steering pump. Use a container for dripping fluid. 3. Connect Pressure Gauge, Special Tool from kit 6815, or equivalent to both hoses using adapter fittings. Connect spare pressure hose, to power steering pump pressure hose fitting. 4. Completely open valve on Special Tool 6815, or equivalent. 5. Start engine and let idle long enough to circulate power steering fluid through flow/pressure test and get air out of fluid. Then shut off engine. 6. Check power steering fluid level, and add fluid as necessary. Start engine again and let idle. 7. Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345 - 552 kPa (50 - 80 psi). The flow meter should read between 1.3 and 1.9 GPM. CAUTION: The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the pump could be damaged. 8. Close valve fully three times and record highest pressure indicated each time. All three readings must be within the specifications and within 345 kPa (50 psi) of each other. NOTE: Power steering pump maximum relief pressure is 9653 to 10342 kPa (1400 to 1500 psi.). If power steering pump pressures are within specifications but not within 345 kPa (50 psi) of each other, then replace power steering pump. - If pressures are within 345 kPa (50 psi) of each other but below specifications, then replace power steering pump. CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time because, pump damage will result. 9. Open test valve. Turn steering wheel to the extreme left and right positions until against the stops, recording the highest indicated pressure at each position. Compare pressure gauge readings to power steering pump specifications. If highest output pressures are not the same against either stop, the steering gear is leaking internally and must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal Steering Gear: Service and Repair Removal The content of this article reflects changes called for in TSB 26-08-98. NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak occurs, the complete steering gear assembly must be replaced. CAUTION: Positioning the steering column in the locked position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 3. With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position. 4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler. 5. Raise vehicle on jack stands or centered on a frame contact type hoist. 6. Remove the front tires. 7. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection. Remove the return hose from the metal tube of the power steering fluid return line. Then allow the remaining power steering fluid to drain from the system through the hose and metal tube. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6681 8. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Tie Rod End Removal From Steering Knuckle Arm 9. Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or MB-991113, or equivalents. HCU To Suspension Cradle Mounting Bolts 10. Remove the 2 bolts and loosen the third attaching the antilock brakes Hydraulic Control Unit (HCU) to the front suspension cradle. Then rotate the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the HCU. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6682 Front Suspension Cradle Plate And Attaching Bolts 11. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle. Then remove the cradle plate from the cradle. 12. If the vehicle is equipped with All-Wheel-Drive, remove the power transfer unit. 13. Remove the bracket attaching the power steering fluid tubes to the front suspension cradle. 14. Using a 18 mm crowfoot, remove the power steering fluid pressure and return lines from the power steering gear. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6683 15. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle. NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear. 16. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin. Install Remover/Installer Special Tool 6831A, or equivalent through the center of the roll pin, securing with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. 17. Separate the intermediate coupler from the shaft of the steering gear. 18. Remove the steering gear assembly from the front suspension cradle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6684 Steering Gear: Service and Repair Installation The content of this article reflects changes called for in TSB 26-08-98. 1. Install the steering gear up in the front suspension cradle, leaving room to install intermediate coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. 3. Install Remover/Installer Special Tool 6831A, or equivalent through the center of the roll pin, securing it with the knurled nut. Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler. 4. Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front suspension cradle mounting bolts and nuts. CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. 5. Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nm (135 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6685 6. Attach the power steering fluid pressure and return lines to the proper fittings on the steering gear. Tighten the power steering fluid line tube nuts to a torque of 31 Nm (275 inch lbs.). 7. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). 8. If the vehicle is equipped with All-Wheel-Drive, install the Ppower transfer unit. CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6686 Front Suspension Cradle Plate And Attaching Bolts 9. Install cradle plate on front suspension cradle and then install the 10 cradle plate to cradle attaching bolts. Tighten the 9 M-14 attaching bolts to a torque of 165 Nm (123 ft. lbs.). Tighten the 1 M-12 attaching bolt to a torque of 108 Nm (80 ft. lbs.). 10. Install the bracket attaching the power steering fluid tubes to the front suspension cradle. 11. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 12. Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose clamp is installed on return tube past the upset bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.). CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube connection portion of both the power steering Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 6687 fluid pressure and return hoses. This is required to prevent the power steering hoses from being overheated. 13. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie strap the heat sleeves to the power steering hoses to keep them in their proper position. 14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 129 Nm (95 ft. lbs.). 15. Lower the vehicle to a level were the interior of vehicle is accessible. 16. Using the intermediate coupler, turn the front wheels of the vehicle to the left until the intermediate coupler shaft is properly aligned with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). CAUTION: Do not use automatic transmission fluid in the power steering system. Only use Mopar (R), Power Steering Fluid or an exact equivalent product. 17. Fill power steering pump fluid reservoir to the proper level. 18. Start the engine and let run for a few seconds. Then turn the engine off. 19. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after running the engine. 20. Raise front wheels of vehicle off the ground. 21. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Then turn the engine off. 22. Add power steering fluid if necessary. 23. Lower the vehicle and turn the steering wheel slowly from lock to lock. 24. Stop the engine. Check the fluid level and refill as required. 25. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure. 26. Fill power steering reservoir to correct level with Mopar (R) Power Steering Fluid, or equivalent. 27. Adjust toe. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Tools and Equipment Special Tool 6831A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Retaining Nut ....................................................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair Tie Rod Boot: Service and Repair NOTE: The removal and installation of the inner tie rod boot must be performed with the steering gear assembly removed from the vehicle. REMOVE 1. Loosen the inner to outer tie rod jam nut. Remove the outer tie rod from the inner tie rod. 2. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with an 11/32 socket, while loosening and removing nut with wrench. Tie Rod End Removal From Steering Knuckle Arm 3. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB-991113 or MB-990635, or equivalent. 4. Remove jam nut from inner tie rod. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 6698 5. Using pliers expand tie rod boot, to inner tie rod clamp and remove from steering gear boot. 6. Remove inner tie rod boot to steering gear clamp. NOTE: After removing inner boot clamps. Use a very small screwdriver to lift boot from its retaining groove in steering gear. Then the boot can be removed from steering gear. INSTALL 1. Install tie rod boot to steering gear clamp on tie rod boot. 2. Install tie rod boot and clamp on inner tie rod. 3. Install tie rod boot over steering gear housing and onto the end of the breather tube. 4. Crimp inner tie rod boot to steering gear clamp using Crimper, Special Tool C4975A, or equivalent. When installing clamp, Special Tool C4975A, or equivalent must have bottom bolt tightened until their is no gap between the 2 bars of the tool. 5. Lubricate inner tie rod boot groove with silicone type lubricant, then install outer boot seal to inner tie rod clamp. (Clamp will have to be loosened for toe adjustment). 6. Install inner to outer tie rod jam nut on inner tie rod. 7. Install outer tie rod on inner tie rod. Do not tighten jam nut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 6699 8. Install tie rod end into the steering knuckle Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 54 Nm (40 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 9. Make toe adjustment by turning inner tie rod. 10. Tighten the inner to outer tie rod jam nut to 75 Nm (55 ft. lbs.) torque. Lubricate tie rod boot groove with silicone type lubricant, before installing outer boot clamp, making sure boot is not twisted. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Service and Repair > Page 6700 Special Tool C-4975A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications Tie Rod End: Specifications Adjusting Sleeve Nut ........................................................................................................................... ..................................................... 75 Nm (55 ft. lbs.) To Steering Knuckle Nut .................................. ........................................................................................................................................ 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End Tie Rod End: Service and Repair Outer Tie Rod End REMOVAL 1. Loosen inner tie rod to outer tie rod jam nut. 2. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with wrench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 6706 Tie Rod End Removal From Steering Knuckle Arm 3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool MB-990635 or MB-991113, or equivalents. 4. Remove outer tie rod end from inner tie rod by unthreading it from the inner tie rod. INSTALLATION 1. Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod. 2. Do not tighten jam nut. 3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, torque tie rod end attaching nut to 54 Nm (40 ft. lbs.). CAUTION: During this procedure do not allow the steering gear boot to become twisted. 4. Adjust the front Toe setting on the vehicle. 5. Tighten tie rod jam nut to 55 Nm (75 ft. lbs.) torque. 6. Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod End > Page 6707 Tie Rod End: Service and Repair Inner Tie Rod End The inner tie rod end is serviced with the rack and pinion assembly only. Chrysler does not provide a separate service procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 6708 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation Ball Joint: Description and Operation The ball joint is pressed into the lower control arm. The ball joint has a non-tapered stud with a notch to provide clearance for the steering knuckle clamp bolt and to provide retention of the ball stud in the steering knuckle. The ball joint stud is clamped and locked into the steering knuckle leg using a pinch bolt. The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Page 6713 Ball Joint: Testing and Inspection With the weight of the vehicle resting on the road wheels, grasp the grease fitting as shown and with no mechanical assistance or added force attempt to rotate the grease fitting. If the ball joint is worn the grease fitting will rotate easily. If movement is noted, replacement of the ball joint is recommended. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) Ball Joint: Service and Repair Ball Joint Replacement (Front Suspension) REMOVE 1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly. 2. Position receiving cup, Special Tool 6758, or equivalent to support lower control arm when removing ball joint assembly. Install Remover, Special Tool 6919, or equivalent on top of the ball joint assembly. 3. Using the arbor press, press the ball joint assembly completely out of the lower control arm. INSTALL NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch in ball joint stud is in the direction shown. This will ease assembly of the ball joint to the steering when installing pinch bolt. 1. By hand, position ball joint into ball joint bore of lower control arm. Be sure ball joint is not cocked in the bore of the control arm, this will cause the ball joint to bind when being pressed into control arm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 6716 2. Position control arm with installed ball joint, in an arbor press with Receiving Cup, Special Tool 6758, or equivalent supporting the lower control arm. Then center Installer, Special Tool 6908-4, or equivalent on the bottom of the ball joint. 3. Carefully align all pieces. Then press the ball joint into the lower control arm until it is completely seated against surface of lower control arm. The ball joint is correctly installed when there is no gap between the ball joint and the lower control arm. Do not apply excessive force against the ball joint or the lower control arm. CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the ball joint seal must be positioned as shown. 4. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 6717 5. Place Installer, Special Tool 6758, or equivalent over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758, or equivalent until seal boot is pressed squarely against top surface of lower control arm. CAUTIONS: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of the ball joint. - After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in damage to the seal boot. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 6718 Ball Joint: Service and Repair Seal Boot Replacement REMOVE 1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly. INSTALL CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the ball joint seal must be positioned as shown. 1. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. 2. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint Replacement (Front Suspension) > Page 6719 CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of the ball joint. CAUTION: After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in damage to the seal boot. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Page 6720 Ball Joint: Tools and Equipment Special Tool 6758 Special Tool 6919 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Testing and Inspection Control Arm Bushing: Testing and Inspection Inspect both control arm bushings for severe deterioration, and replace if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Control Arm Bushing: Service and Repair Front REMOVE 1. Remove the lower control arm from the front suspension cradle. 2. Securely mount the lower control arm in a vise. 3. Assemble or removal of the front bushing, the Bushing Receiver, Special Tool 6908-2, Bushing Remover, Special Tool 6908-1, Nut, Special Tool 6908-3 thrust washer, or equivalents, threaded rod and small nut, as shown on the lower control arm and front bushing. 4. To remove front bushing from lower control arm, hold the threaded rod stationary and tighten the Nut, Special Tool 6908-3, or equivalent. This will force the front bushing out of the lower control arm and into Bushing Receiver, Special Tool 6908-2, or equivalent. INSTALL 1. Securely mount the lower control arm in a vise. NOTE: The lower control arm front bushing is a directional bushing. It must be installed in the lower control arm positioned as shown. 2. Position the front bushing in the lower control arm so that the 2 rubber blocks on the bushing are positioned horizontally as shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front > Page 6727 3. Assemble for installation of the front bushing, the Bushing Receiver, Special Tool 6908-5, Bushing Installer, Special Tool 6908-4, Nut, Special Tool 6908-3 thrust washer, or equivalents, threaded rod and small nut, as shown on the lower control arm and front bushing. 4. To install the front bushing in lower control arm, hold the threaded rod stationary and tighten the Nut, Special Tool 6908-3, or equivalent. This will pull the front bushing into the lower control arm. 5. Continue pulling the bushing into the lower control arm until bushing is seated squarely against the lower control arm and there is no gap between the bushing and the lower control arm. 6. Install the lower control arm on the front suspension cradle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front > Page 6728 Control Arm Bushing: Service and Repair Rear REMOVE 1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm in a vise without using excessive clamping force. 3. Using a sharp knife, (such as a razor) slit the bushing lengthwise to allow its removal from the lower control arm. 4. Remove the bushing from the lower control arm. INSTALL CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified below to the control arm bushing. 1. Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing. This will aid in the installation of the bushing on the lower control arm. 2. With the lower control arm held securely in a vise, install bushing on lower control arm. Install bushing by pushing and rocking the bushing until it is fully installed on lower control arm. Be sure when bushing is installed it is past the upset on the end of the lower control arm. 3. The rear bushing of the lower control arm, when correctly installed, is to be positioned on the lower control arm as shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Page 6729 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications To Body Attaching Bolts ...................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12 ............................................................................................................................................ 108 Nm (80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14 .......................................................................................................................................... 166 Nm (123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts ............................................................................................................................................... 165 Nm (123 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Page 6733 Cross-Member: Description and Operation This vehicle uses a one piece cast aluminum cradle for the front suspension. The cradle is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. The cradle is mounted to the front frame rails at four points, two on each side of the vehicle. The cradle is isolated from the body of the vehicle using four isolators, one located at each mounting bolt location. CAUTION: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the cradle that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil thread insert, or equivalent which has been specifically developed for this application. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Page 6734 Cross-Member: Service and Repair CAUTION: When performing this procedure use only the thread inserts which are specified in the Mopar (R) Parts Catalog, or equivalent for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. SUSPENSION CRADLE THREAD REPAIR PROCEDURE The threaded holes in the front suspension cradle, if damaged, can repaired by installing a Heli-Coil (R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the suspension crossmember to be repaired, eliminating the need to replace the crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar (R) Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8 x 1.25 and M10 x 1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8 x 1.25 THREAD - 8.3 mm (5/16 inch) Drill Bit - 120° Countersink - Heli-Coil (R) Tap #4863-8 - Heli-Coil (R) Gage #4624-8 - Heli-Coil (R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10 x 1.5 THREAD - 10.5 mm (25/64 inch) Drill Bit - 120° Countersink - Heli-Coil (R) Tap #4863-10 - Heli-Coil (R) Gage #4624-10 - Heli-Coil (R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Ball Joint Stud To Steering Knuckle Nut/Bolt ..................................................................................................................................... 136 Nm (100 ft. lbs.) Wheel Stop .............................................................................................................................. ................................................................. 95 Nm (70 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6738 Front Steering Knuckle: Service Precautions CAUTION: The front suspension knuckle is not a repairable component of the vehicles front suspension IT MUST BE REPLACED. If bent, broken or damaged in any way, do not attempt to straighten or repair the steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Page 6739 Front Steering Knuckle: Description and Operation The steering knuckle is a single casting with legs machined for attachment of the strut damper, steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has the front hub/bearing assembly mounted to it. The hub is positioned through the bearing and knuckle, with the constant velocity stub shaft splined through the hub. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire assembly from the vehicle. 4. Remove the wave washer from the end of the stub axle. CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires. 5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut. 6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6742 7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle. 8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly. Do not allow the brake caliper assembly to hang by the brake flex hose. 9. Remove the brake rotor from the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6743 10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench. Tie Rod End Removal From Steering Knuckle Arm 11. Remove the tie rod end from steering knuckle using Remover, Special Tool MB-991113, or equivalent. 12. Remove the front wheel speed sensor from the steering knuckle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6744 13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt when assembling the steering knuckle to the ball joint , the pinch bolt must be installed from the rear facing the front on the vehicle. 14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle. 15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6745 16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. 17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the steering knuckle from the strut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6746 Front Steering Knuckle: Service and Repair Installation 1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to Transmission and Drivetrain. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. NOTE: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket. 2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn. 3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6747 4. Install a NEW steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt and nut to a torque of 145 Nm (105 ft. lbs.). 5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6748 6. Install braking disc on hub and bearing assembly. 7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment. 8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake caliper assembly attaching bolts to a torque of 35 Nm (30 ft. lbs.). 9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 6749 10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor attaching bolt to a torque of 7 Nm (60 inch lbs.). 11. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 12. Lower vehicle. 13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 203 Nm (150 ft. lbs.). 14. Install the spring wave washer on the end of the stub axle. 15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut lock as shown. 16. Set front Toe on vehicle to required specification. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair Lateral Stabilizer Rod: Service and Repair REMOVE 1. Remove the nut and bolt mounting the track bar to the rear axle. 2. Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar from the track bar mount. INSTALL 1. Install the track bar first into the body mount for the track bar. Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. 2. Install the track bar into its mounting bracket on the rear axle. Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. 3. Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels. Tighten both track bar attaching bolts to a torque of 95 Nm (70 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Specifications Stabilizer Bushing: Specifications FRONT: Bushing Retainer Attaching Bolts ......................................................................................................................................................... 70 Nm (50 ft. lbs.) REAR: Bushing Retainer Attaching Bolts ......................................................................................................................................................... 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Description and Operation > Front Stabilizer Bushing: Description and Operation Front Attachment of the stabilizer bar to the front suspension cradle is through 2 rubber-isolator bushings and bushing retainers. The stabilizer bar to Mc Pherson strut assembly attachment is done utilizing a sway bar attaching link. All parts of the stabilizer bar are serviceable, and the stabilizer bar to crossmember bushings are split for easy removal and installation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Description and Operation > Front > Page 6759 Stabilizer Bushing: Description and Operation Rear Attachment to the rear axle tube, and rear flame rails is through rubber-isolated bushings. All parts are serviceable, and the stabilizer bar to axle bushings are split for easy removal and installation. The split in the bushing should be positioned up when the stabilizer bar is installed on the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Description and Operation > Page 6760 Stabilizer Bushing: Service and Repair If stabilizer bar to front suspension cradle bushings require replacement at time of inspection install new bushings before installing stabilizer bar. Stabilizer bar bushings are replaced by opening the slit on the bushings and peeling them off the stabilizer bar. Install new bushings on stabilizer bar, by spreading bushing at slit and forcing them on stabilizer bar. NOTE: Bushings must be installed on stabilizer bar so the square corner of the bushing will be down and slit in bushing will be facing the rear of the vehicle when the stabilizer is installed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound Stabilizer Link: Customer Interest Front Suspension - Knock/Squawk Sound NUMBER: 02-004-01 GROUP: Suspension DATE: July 6, 2001 SUBJECT: Knock/Squawk Sound From Front Suspension OVERVIEW: This bulletin involves installing new front sway bar link assemblies. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: 1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low speed turn such as a parking lot maneuver. 2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy roads. DIAGNOSIS: 1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway bar link. Listen or feel for the condition described above while the wheel is being turned. If the condition is present, perform the Repair Procedure. 2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any loose, damaged or worn components and test drive vehicle. It the condition is still present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. 2. Remove both front wheels. 3. Remove the upper and lower sway bar link nuts and remove the sway bar link. CAUTION: WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A # 40 TORX BIT INTO THE END OF THE STUD. 4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.). 5. Perform steps 3 and 4 for the other sway bar link. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.) and then use a criss-cross pattern again to tighten to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound > Page 6769 a final torque of 135 N.m (100 ft. lbs.). 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound Stabilizer Link: All Technical Service Bulletins Front Suspension - Knock/Squawk Sound NUMBER: 02-004-01 GROUP: Suspension DATE: July 6, 2001 SUBJECT: Knock/Squawk Sound From Front Suspension OVERVIEW: This bulletin involves installing new front sway bar link assemblies. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) 2001 (RS) Town & Country/Caravan/Voyager 2001 (RG) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: 1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low speed turn such as a parking lot maneuver. 2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy roads. DIAGNOSIS: 1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway bar link. Listen or feel for the condition described above while the wheel is being turned. If the condition is present, perform the Repair Procedure. 2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any loose, damaged or worn components and test drive vehicle. It the condition is still present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise the vehicle on a frame contact hoist. 2. Remove both front wheels. 3. Remove the upper and lower sway bar link nuts and remove the sway bar link. CAUTION: WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING A # 40 TORX BIT INTO THE END OF THE STUD. 4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.). 5. Perform steps 3 and 4 for the other sway bar link. 6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.) and then use a criss-cross pattern again to tighten to Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul > 01 > Front Suspension - Knock/Squawk Sound > Page 6775 a final torque of 135 N.m (100 ft. lbs.). 7. Lower vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Technical Service Bulletins > Page 6776 Stabilizer Link: Specifications FRONT: Attaching Nuts ..................................................................................................................................... ................................................. 88 Nm (65 ft. lbs.) REAR: Attaching Nuts ..................................................................................................................................... ................................................. 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Description and Operation > Front Stabilizer Link: Description and Operation Front The stabilizer bar attaching links are used to attach each end of the stabilizer bar to the front strut assemblies. This reduces the fore-and-aft rate of the stabilizer bar from the rest of the vehicle's front suspension. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Description and Operation > Front > Page 6779 Stabilizer Link: Description and Operation Rear The 2 rubber isolated link arms are connected to the rear frame rails by brackets. These brackets are bolted to the bottom of the frame rails. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 6788 TIME ALLOWANCE FAILURE CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 6794 TIME ALLOWANCE FAILURE CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and Repair > Front Crossmember Subframe: Service and Repair Front Crossmember REMOVAL AND INSTALLATION FRONT CROSSMEMBER The front suspension crossmember must be installed in the design location to achieve proper front end suspension alignment. If the crossmember is removed without applying reference marks on the frame rails, align the crossmember according to the dimensions provided in this group. NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through a Mopar Parts supplier. REMOVAL 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove knee blocker reinforcement. 4. Position steering so front wheels are straight ahead. CAUTION: DO NOT ROTATE STEERING WHEEL AFTER DISENGAGING LOWER COUPLING FROM STEERING GEAR, DAMAGE TO AIRBAG CLOCK SPRING CAN RESULT. Steering Coupling Boot 5. Remove clinch bolt holding steering column coupling to steering gear shaft. 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist and support vehicle on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using hose pinch-off pliers C-4390, pinch power steering oil return hose off between the cross-member coupling and the pump. 10. Loosen hose clamp at the crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump. Remove flare nut holding high pressure hose to back of pump. 13. Separate high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts holding anti-lock brake sensor leads to crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. Refer to Steering and Suspension. 18. Disconnect lower ball joints from lower control arms. Refer to Steering and Suspension. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and Repair > Front Crossmember > Page 6799 Rear Engine Mount 19. Remove bolt holding rear engine mount to crossmember. 20. Using paint or grease pencil, mark outline of crossmember on frame rails to aid installation. Crossmember 21. Support crossmember on suitable lifting device. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and Repair > Front Crossmember > Page 6800 Crossmember Mount 22. Remove bolts holding crossmember to front frame rails. Crossmember 23. Remove crossmember from vehicle. INSTALLATION NOTE: If crossmember requires replacement. Refer to Steering and Suspension, to transfer steering and suspension components. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and Repair > Front Crossmember > Page 6801 Crossmember 1. Support crossmember on suitable lifting device. 2. Position crossmember to vehicle. 3. Loosely install bolts to hold crossmember to front frame rails. 4. Align crossmember to previously made marks on frame rails. 5. Tighten bolts holding crossmember to frame rails. 6. Install bolt holding rear engine mount to cross-member. 7. Connect lower ball joints to lower control arms. Refer to Steering and Suspension. 8. Connect stabilizer bar links to ends of stabilizer bar. Refer to Steering and Suspension 9. Install bolts to hold anti-lock brake sensor leads to crossmember. 10. Install high pressure hose to pump. 11. Connect return hose to metal tube. 12. Tighten hose clamp at the crossmember coupling. 13. Remove pinch-off pliers. 14. Position steering so front wheels are straight ahead. 15. Install steering column coupling to telescoping steering gear shaft. 16. Install clinch bolt to hold steering column coupling to steering gear shaft. 17. Install knee blocker reinforcement. 18. Install steering column lower cover from instrument panel. 19. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and Repair > Front Crossmember > Page 6802 Subframe: Service and Repair Front Crossmember Mount Bushings FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of crossmember on frame rails. 2. Loosen bolts holding crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lube or soap to replacement bushing. 2. Insert lower half of bushing into square hole in crossmember. 3. Place upper half of bushing on top of cross-member aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into crossmember and upper bushing. 7. Install bolt to hold bushing and crossmember to frame rail hand tight. 8. Align crossmember to reference marks on frame rails. 9. Tighten crossmember to frame rails attaching bolts to 163 Nm 120 ft. lbs. torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications Spring Plate To Axle Attaching Bolts .................................................................................................................................................... 108 Nm (80 ft. lbs.) Rear Mount To Body Bolts .......................................................................................... ............................................................................ 61 Nm (45 ft. lbs.) Front Mount To Body Bolts ....... .............................................................................................................................................................. 61 Nm (45 ft. lbs.) To Front Hanger Mounting Nut ............................................................................................................................................................ 156 Nm (115 ft. lbs.) Shackle Plate Nuts ............................................................................................. ....................................................................................... 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 6806 Suspension Spring ( Coil / Leaf ): Description and Operation Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. During service procedures when both springs are removed, mark springs to ensure installation in original position. Each coil spring comes with a plastic sleeve on the second coil of the spring. This plastic sleeve is a noise insulator for the coil spring. NOTE: If coil springs require replacement, be sure that the springs needing replacement are replaced with springs meeting the correct load rating for the vehicle and its specific options. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing 1. Install leaf spring in a proper holding fixture. 2. Install leaf spring press Special Tool C-4212-F, or equivalent. 3. Install adapter Special Tool C-4212-3, or equivalent. 4. Tighten leaf spring press until bushing is extracted from leaf spring. 5. Remove leaf spring press from leaf spring. 6. Insert replacement bushing into the leaf spring eye. Verify that the bushing flange is on the outboard side of the leaf spring. 7. Install leaf spring press Special Tool C-4212-F, or equivalent. 8. Install adapter Special Tool C-4212-4, or equivalent. 9. Tighten leaf spring press until bushing flange bottoms solidly against leaf spring eye. 10. Remove leaf spring press and adapter. 11. Bend the bushing tabs so that they are contacting the leaf spring. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6809 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement Removal 1. Raise vehicle on frame contact hoist to a comfortable working position. 2. Support axle with a jack stand. Pad should just contact axle. 3. Begin removal of the shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). 4. Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. 5. Loosen and remove the axle plate bolts from the rear axle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6810 6. Remove the axle plate from the rear axle and the leaf spring. 7. Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. 8. Loosen and remove the 4 bolts from the front mount of the leaf spring. 9. Loosen and remove the nuts from the spring hanger for the rear leaf spring. Then remove the hanger plate from the hanger and remove the spring from the spring hanger. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6811 10. Remove the leaf spring from the vehicle. 11. Loosen and remove the pivot bolt from the front mount of the rear leaf spring. Installation 1. Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten. CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. 2. Raise front of spring and install four hanger bolts, tighten to 61 Nm (45 ft. lbs.) torque. 3. Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. 4. Verify lower leaf spring isolator is in position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6812 5. Raise axle assembly into correct position with axle centered under spring locator post. 6. Verify that the leaf spring isolator is correctly positioned in the axle plate. 7. Install axle plate on the spring. 8. Install axle plate bolts. Tighten bolts to 108 Nm (80 ft. lbs.) torque. 9. Install shock absorber bolts. Do not tighten. 10. Lower vehicle to floor so that the full weight of the vehicle is supported by the tires. 11. Tighten component fasteners as follows: - Front pivot bolt: 156 Nm (116 ft. lbs.) - Shackle nuts: 61 Nm (45 ft. lbs.) - Shock absorber bolts: 101 Nm (75 ft. lbs.) 12. If the vehicle is not equipped with antilock brakes, raise vehicle and connect the actuator for the height sensing proportioning valve on the rear leaf spring. Adjust the height sensing proportioning valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6813 Suspension Spring ( Coil / Leaf ): Service and Repair Mount Replacement Front REMOVE 1. Loosen the pivot bolt attaching the front of the leaf spring to the spring mount. 2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand support the weight of the axle and leaf spring. 3. Remove the lower mounting bolt from the shock absorber. 4. Remove the bolts attaching the leaf spring front mount to the body of the vehicle. 5. Lower the leaf spring and remove the front mount from the spring. INSTALLATION 1. For installation, reverse removal procedure. Do not tighten front through bolt fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten leaf spring front mount bolts to 61 Nm (45 ft. lbs.). Tighten leaf spring front through bolt to 156 Nm (115 ft. lbs.). Rear REMOVE 1. Remove the attaching nuts and bolts from the leaf spring rear shackle. 2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. 3. Remove the lower mounting bolt from the shock absorber. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Bushing > Page 6814 4. Remove the bolts attaching the leaf spring rear mount to the body of the vehicle. 5. Lower the jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing. INSTALL 1. For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten rear spring mount bolts to 61 Nm (45 ft. lbs.). Tighten shackle nuts to 61 Nm (45 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise Technical Service Bulletin # 02-10-98 Date: 980925 Front Strut Bearings - Squeaking/Chirping Noise NO: 02-10-98 GROUP: Suspension DATE: Sept. 25, 1998 SUBJECT: Squeaking Noise From Strut Bearing(s) MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998. SYMPTOM/CONDITION: A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s) when turning the steering wheel or when the vehicle is driven over any irregularities in the road surface. DIAGNOSIS: With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180° apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower. Parts Information: AR (2) 04684418 Bearing, Strut Upper Pivot POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-39-93 One Side 0.9 Hrs. 02-05-39-94 Two Sides 1.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the strut upper pivot bearing(s). WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of the service manual, for the required lifting procedure to be used for this vehicle. 2. Remove the front wheel and tire assembly from the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6823 3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Figure 1). NOTE: WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2. 4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6824 6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle (Figure 4). 7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment (PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed (Figure 5 and 6). WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 8. Compress the coil spring until all coil spring tension is removed from the upper mount. 9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 10. Remove the upper mount from the strut shaft. 11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight up. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6825 12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7). Be sure the pivot bearing is sitting flat on the spring seat once mounted. 13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat (Figure 6). Loosely install the retaining nut on the strut shaft. 14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.). 15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3). NOTE: IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING THE FRONT OF THE VEHICLE. 18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. NOTE: WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD (FIGURE 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6826 20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a torque of 88 Nm (65 ft. lbs.) (Figure 8). 21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.). 22. Install the wheel/tire assembly on the vehicle. 23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 24. Repeat step 2 through 23 for the other side strut, if necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps Suspension Strut / Shock Absorber: Customer Interest Rear Shock Absorber - Rattles on Bumps NO: 02-09-98 GROUP: Suspension DATE: Aug. 28, 1998 SUBJECT: Load Leveling Shock Bushing Service MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH LOAD LEVELING SHOCKS (SALES CODE SER). SYMPTOM/CONDITION: Rattle noise from rear of the vehicle when driving over road bumps. DIAGNOSIS: Check all rear shock bolts for proper torque, 101 Nm (75 ft. lbs.). Check upper shock bushing for wear, rubber debris around bushing or holes and voids in rubber. If the bushing has evidence of wear, perform the Repair Procedure. PARTS REQUIRED: 2 05013474AA Bushing, Upper Load Leveling REPAIR PROCEDURE: This bulletin involves replacing the upper load leveling shock bushings 1. Using the procedure outlined in group 2 of the appropriate service manual, remove the rear shocks. 2. Secure ball joint press, special tool C-4212F, in a bench vise. Install the receiver, special tool 8526-1, into the cup of C-4212F, and tighten the set screw. Install the driver, special tool 8526-2, on the tip of the C-4212F screw drive, (Figure 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6831 3. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 2). 4. Tighten the screw drive until the driver contacts the outer circumference of the bushing evenly. Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the receiver. 5. Back off the screw drive and remove the bushing from the receiver. 6. Install the driver, special tool 8526-2, on the tip of the ball joint press screw drive as shown in Figure 3. Position the driver this way to seat the bushing to its correct depth. 7. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 4). 8. Position the bushing between the shock absorber eye and the driver. Tighten the screw drive until the driver, bushing, and shock absorber eye are touching and squarely aligned. 9. Press the bushing into the shock absorber eye until the driver bottoms against the face of the eye. Back off the ball Joint press screw drive and remove the shock absorber from the press. 10. Repeat steps 2 through 9 for the other shock. 11. Using the procedure outline in section 2 of the appropriate service manual, install the rear shocks. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6832 Labor Operation No: 02-15-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise Technical Service Bulletin # 02-10-98 Date: 980925 Front Strut Bearings - Squeaking/Chirping Noise NO: 02-10-98 GROUP: Suspension DATE: Sept. 25, 1998 SUBJECT: Squeaking Noise From Strut Bearing(s) MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998. SYMPTOM/CONDITION: A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s) when turning the steering wheel or when the vehicle is driven over any irregularities in the road surface. DIAGNOSIS: With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180° apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower. Parts Information: AR (2) 04684418 Bearing, Strut Upper Pivot POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-05-39-93 One Side 0.9 Hrs. 02-05-39-94 Two Sides 1.6 Hrs. FAILURE CODE: P8 - New Part Repair Procedure This bulletin involves replacing the strut upper pivot bearing(s). WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubrication and Maintenance section of the service manual, for the required lifting procedure to be used for this vehicle. 2. Remove the front wheel and tire assembly from the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6838 3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets (Figure 1). NOTE: WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2. 4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6839 6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle (Figure 4). 7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment (PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed (Figure 5 and 6). WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 8. Compress the coil spring until all coil spring tension is removed from the upper mount. 9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 10. Remove the upper mount from the strut shaft. 11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight up. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6840 12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7). Be sure the pivot bearing is sitting flat on the spring seat once mounted. 13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat (Figure 6). Loosely install the retaining nut on the strut shaft. 14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.). 15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.). CAUTION: THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS STATIONARY IN THE STEERING KNUCKLES. 17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3). NOTE: IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING THE FRONT OF THE VEHICLE. 18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. NOTE: WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN THE END OF THE STUD (FIGURE 8). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6841 20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a torque of 88 Nm (65 ft. lbs.) (Figure 8). 21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.). 22. Install the wheel/tire assembly on the vehicle. 23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 24. Repeat step 2 through 23 for the other side strut, if necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps Suspension Strut / Shock Absorber: All Technical Service Bulletins Rear Shock Absorber - Rattles on Bumps NO: 02-09-98 GROUP: Suspension DATE: Aug. 28, 1998 SUBJECT: Load Leveling Shock Bushing Service MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH LOAD LEVELING SHOCKS (SALES CODE SER). SYMPTOM/CONDITION: Rattle noise from rear of the vehicle when driving over road bumps. DIAGNOSIS: Check all rear shock bolts for proper torque, 101 Nm (75 ft. lbs.). Check upper shock bushing for wear, rubber debris around bushing or holes and voids in rubber. If the bushing has evidence of wear, perform the Repair Procedure. PARTS REQUIRED: 2 05013474AA Bushing, Upper Load Leveling REPAIR PROCEDURE: This bulletin involves replacing the upper load leveling shock bushings 1. Using the procedure outlined in group 2 of the appropriate service manual, remove the rear shocks. 2. Secure ball joint press, special tool C-4212F, in a bench vise. Install the receiver, special tool 8526-1, into the cup of C-4212F, and tighten the set screw. Install the driver, special tool 8526-2, on the tip of the C-4212F screw drive, (Figure 1). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6846 3. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 2). 4. Tighten the screw drive until the driver contacts the outer circumference of the bushing evenly. Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the receiver. 5. Back off the screw drive and remove the bushing from the receiver. 6. Install the driver, special tool 8526-2, on the tip of the ball joint press screw drive as shown in Figure 3. Position the driver this way to seat the bushing to its correct depth. 7. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears the shock absorber body (Figure 4). 8. Position the bushing between the shock absorber eye and the driver. Tighten the screw drive until the driver, bushing, and shock absorber eye are touching and squarely aligned. 9. Press the bushing into the shock absorber eye until the driver bottoms against the face of the eye. Back off the ball Joint press screw drive and remove the shock absorber from the press. 10. Repeat steps 2 through 9 for the other shock. 11. Using the procedure outline in section 2 of the appropriate service manual, install the rear shocks. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6847 Labor Operation No: 02-15-15-90 0.9 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Mounting Bolts (All) ............................................................................................................................. ................................................. 101 Nm (75 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 6850 Suspension Strut / Shock Absorber: Specifications Struts Tower Attaching Nuts .......................................................................................................................... ............................................... 28 Nm (250 inch lbs.) Clevis Bracket To Steering Knuckle .................................................................................................................................. 88 Nm (65 ft. lbs.) Plus 1/4 Turn Shaft Nut ............................................................................................................... .................................................................................. 100 Nm (75 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front Suspension Strut / Shock Absorber: Description and Operation Front The front suspension of the vehicle is supported by coil springs positioned around the strut assembly. The springs are contained between an upper seat, located just below the top strut mount assembly and a lower spring seat on the strut fluid reservoir. The top of each strut assembly is bolted to the upper fender reinforcement (strut tower) through a rubber isolated mount. The bottom of the strut assembly attaches to the steering knuckle with two through bolts. Caster is a fixed setting on all vehicles and is not adjustable when an alignment is performed. In the event the camber setting on a vehicle requires adjustment, a service strut is available which will provide a method by which the camber can be adjusted. The strut assemblies on this vehicle are inter-connected by the front stabilizer bar through 2 link assemblies attaching the struts to the stabilizer bar. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Front > Page 6853 Suspension Strut / Shock Absorber: Description and Operation Shock Absorber REAR LOAD LEVELING A new type of load-leveling shock is available. Description The self leveling shock absorbers are a self-contained vehicle leveling system and shock absorber combined. Requirements It does not require an external compressor, hoses, height leveling sensors, etc. It uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping, which is just the extension and compression of the shock absorber. Design On the outside, it looks like a larger than normal shock absorber. Internally, it consists of a hydraulic pump and gas-spring cushion for leveling, as well as the normal shock absorbing mechanism. All the height leveling sensors, pump, etc., are contained inside the shocks. Mounting The shocks are mounted at an angle, parallel to the springs and forward at the top. This design provides greater stability in addition to controlling ride motion. These new load-leveling shock absorbers use longer fasteners than the standard shock absorbers, although the fasteners are longer, the torque specifications are the same. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 6854 Suspension Strut / Shock Absorber: Testing and Inspection 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust boots. 3. Inspect the coil spring isolator on the lower spring seat, for any signs of damage or deterioration. 4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replacement REMOVAL/INSTALLATION 1. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type hoist. 2. Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle. NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. 3. Remove the shock absorber lower mounting bolt. 4. While holding shock absorber, remove the shock absorber upper mounting bolt. 5. To install the shock absorber use the reverse sequence of its removal. 6. Lower the vehicle to the ground so the full weight of the vehicle is supported by the suspension. 7. Tighten the upper and lower shock absorber mounting bolt to their specified torques. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6857 Suspension Strut / Shock Absorber: Service and Repair Replacement Removal WARNING: Do not remove the nut from the strut rod while strut assembly is installed in vehicle, or before strut assembly spring is compressed. 1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the wheel and tire assembly from location on front of vehicle requiring strut removal. 3. If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. 4. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets. NOTE: When removing nut from stud of stabilizer bar attaching link, do not allow stud to rotate. Hold stud from rotating by inserting a Torx Plus 40IP bit in the end of the stud as shown. 5. Remove the stabilizer bar attaching link from the bracket on the strut assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6858 6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts. 7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower. Installation 1. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 Nm (250 inch lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6859 2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts. If strut assembly is attached to steering knuckle using a cam bolt, the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Also, attaching bolts should be installed with the nuts facing the front of the vehicle. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after specified torque is met. 3. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link to strut bracket attaching nut. NOTE: When torquing nut on stud of stabilizer bar attaching link, do not allow stud to rotate. Hold stud from rotating by inserting a Torx Plus 401P bit in the end of the stud as shown. 4. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40IP bit and crowfoot as shown to a torque of 88 Nm (65 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6860 5. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets. Tighten the routing bracket attaching bolts to a torque of 13 Nm (10 ft. lbs.). 6. Install the wheel/tire assembly on the vehicle. 7. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6861 Suspension Strut / Shock Absorber: Service and Repair Overhaul Disassembly NOTE: The Mc Pherson Strut must be remove from the vehicle for it to be disassembled and assembled. 1. Clamp strut assembly in vise, with strut in a vertical position. Do not clamp reservoir of strut assembly in vise, only clamp strut assembly using strut clevis bracket. 2. Mark coil spring and strut assembly right or left, according to which side of vehicle strut was removed from, and which strut coil spring was removed from. Compressing Strut Assembly Coil Spring WARNING: Do not remove strut rod nut, before strut assembly coil spring is compressed, removing spring tension from upper spring seat and bearing assembly. - When compressing coil spring for removal from strut assembly, the upper spring seat and second coil of the coil spring must be captured by the jaws of the coil spring compressor. 3. Compress strut assembly coil spring, using Pentastar Service Equipment Spring Compressor, 7522A or equivalent. Be sure the top and bottom attachment shoe selected, properly fit the coil spring. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6862 4. Install Socket, Strut Nut, Special Tool 6864 on the Strut shaft retaining nut. Then install a 10 mm socket on the hex of the strut damper shaft. While holding strut shaft from turning, remove the strut shaft retaining nut. Strut Assembly Upper Mount 5. Remove the upper strut mount from the strut assembly. 6. Release the coil spring from the spring compressor. Then remove the spring compressor from the coil spring. 7. Remove the upper spring seat and the pivot bearing as an assembly from the coil spring. Then remove the coil spring from the strut assembly. Mark left and right springs for installation back on correct side of vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6863 8. Remove the dust shield and the jounce bumper as an assembly from strut shaft. The dust shield can not be removed from the jounce bumper until after it is removed from strut shaft. 9. Remove the jounce bumper from the dust shield. Jounce bumper is removed from dust shield by collapsing dust shield until jounce bumper can be grabbed onto and then pulled out of the dust boot. 10. Remove the spring isolator from the strut assembly lower spring seat. 11. Inspect strut damper for any condition of shaft binding over full stroke of the shaft. 12. Inspect the strut mount and the upper spring seat assembly for the following: - Mount for cracks and distortion and retaining studs for any sign of damage. - Severe deterioration of rubber isolator, - Binding strut assembly pivot bearing. If pivot bearing is replaced it is to be installed with the larger diameter end of bearing facing up. - Inspect dust shield for rips and/or deterioration. - Inspect jounce bumper for cracks and signs of deterioration. 13. Replace any components of the strut assembly found to be worn or defective during the inspection, before re-assembling the strut. Assembly 1. Clamp strut assembly in vise, with strut in a vertical position. Do not clamp reservoir of strut assembly in vise, only clamp the strut assembly in Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6864 vise using clevis bracket. 2. Install the spring isolator on the strut lower spring seat. When installing the spring isolator, be sure the 2 retaining tabs on the spring isolator are installed in the 2 holes in the spring seat. When properly installed, the oversize holes in the spring seat should line up with the holes in the spring isolator. WARNING: If a replacement coil spring is to be installed on the strut assembly, the first full top and bottom coil of the spring must be captured by the jaws of the coil spring compressor. 3. Install the jounce bumper on the shaft of the strut assembly. Jounce bumper is to be installed with the small end of the jounce bumper pointing down. 4. Install the dust shield on the strut assembly. After dust shield is installed on strut, collapse dust shield down on top of jounce bumper until jounce bumper snaps into dust shield. Then return the dust shield to its fully extended length. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6865 5. Install coil spring onto strut. Spring is to be installed with the end of the bottom coil aligned with the clevis bracket on the strut assembly. 6. Install the upper spring seat on the coil spring. Spring seat must be installed with the notch in the spring seat aligned with the clevis bracket on the strut assembly. 7. Compress strut assembly coil spring, using Pentastar Service Equipment Spring Compressor, 7522A or equivalent. Be sure the top and bottom attachment shoe selected, properly fit the coil spring. 8. Install the strut assembly pivot bearing on the top of the upper spring seat. Bearing must be installed on spring seat with the smaller diameter side of the pivot bearing toward the spring seat. Also, be sure the pivot bearing is sitting flat on the spring seat. 9. Install the strut mount on the upper spring seat of the strut assembly. Then loosely install the nut on strut shaft. WARNING: The following 2 steps must be completely done before spring compressor is released from the coil spring. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Replacement > Page 6866 10. Install Socket, Strut Nut, Special Tool 6864 on the strut shaft retaining nut. Then install a 10 mm socket on the hex of the strut damper shaft. While holding strut shaft from turning, torque strut shaft retaining nut to 94 Nm (70 ft. lbs.). 11. Loosen Spring Compressor, Special Tool GP-2020-S2.6, or equivalent until top coil of spring is fully seated against upper spring seat. Then relieve all tension from spring compressor and remove spring compressor from strut assembly spring. 12. Install the strut assembly back in the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Page 6867 Special Tool 6864 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension - Thumping Noise Suspension Travel Bumper: Customer Interest Rear Suspension - Thumping Noise NO: 02-09-97 Rev. A GROUP: Suspension DATE: Oct. 24, 1997 SUBJECT: Thumping Noise At Rear Of Vehicle During Cold Operations THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB OR ALL WHEEL DRIVE (AWD).** SYMPTOM/CONDITION: Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has been in very cold temperatures (below 100 F.) for three hours or longer. DIAGNOSIS: After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over small bumps and listen for a thumping noise. The condition should improve if the temperature increases or the after the vehicle has been driven a few miles. If the thumping noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD) AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD) **NOTE: DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.** REPAIR PROCEDURE: This bulletin involves replacing the rear axle jounce bumpers. 1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise. 2. Separate the jounce bumper from the vehicle and discard. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension - Thumping Noise > Page 6876 3. Install the appropriate revised jounce bumper specified in Parts Required. 4. Repeat steps 1 through 3 for the other side jounce bumper. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-04-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension - Thumping Noise Suspension Travel Bumper: All Technical Service Bulletins Rear Suspension - Thumping Noise NO: 02-09-97 Rev. A GROUP: Suspension DATE: Oct. 24, 1997 SUBJECT: Thumping Noise At Rear Of Vehicle During Cold Operations THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) **NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB OR ALL WHEEL DRIVE (AWD).** SYMPTOM/CONDITION: Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has been in very cold temperatures (below 100 F.) for three hours or longer. DIAGNOSIS: After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over small bumps and listen for a thumping noise. The condition should improve if the temperature increases or the after the vehicle has been driven a few miles. If the thumping noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD) AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD) **NOTE: DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.** REPAIR PROCEDURE: This bulletin involves replacing the rear axle jounce bumpers. 1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise. 2. Separate the jounce bumper from the vehicle and discard. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension - Thumping Noise > Page 6882 3. Install the appropriate revised jounce bumper specified in Parts Required. 4. Repeat steps 1 through 3 for the other side jounce bumper. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-04-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Technical Service Bulletins > Page 6883 Suspension Travel Bumper: Specifications To Frame Rail ...................................................................................................................................... ............................................... 33 Nm (290 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Standard Suspension Travel Bumper: Service and Repair Standard NOTES: - There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with. - The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail. REMOVAL 1. Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. 2. Remove the jounce bumper from the frame rail. INSTALLATION 1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a torque of 33 Nm (290 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Standard > Page 6886 Suspension Travel Bumper: Service and Repair Heavy Duty NOTES: - There are two types of jounce bumpers available depending on which suspension option the vehicle is equipped with. - The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a weld nut located on the frame rail. REMOVAL 1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2. Remove the jounce bumper from the frame rail. INSTALLATION 1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm (290 inch lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications Trailing Arm: Specifications To Axle And Mounting Bracket Pivot Bolt .............................................................................................................................................. 95 Nm (70 ft. lbs.) Bracket To Body Attaching Bolt .............................................................................................................................................................. 61 Nm (45 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 6890 Trailing Arm: Description and Operation On applications of this vehicle that are equipped with single leaf rear springs a track bar is used on the rear axle. The track bar connects the rear axle to the frame/body of the vehicle. The track bar is isolated form the body of the vehicle by an isolator bushing located in each end of the track bar. The track bar prevents excessive side to side movement of the rear axle. The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Specifications > Page 6891 Trailing Arm: Service and Repair REMOVE 1. Remove the track bar from the track bar mount. 2. Remove the three bolts attaching the track bar mount to the body. INSTALLATION 1. For installation, reverse removal procedure. Tighten bolts to 61 Nm (45 ft. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6895 Wheel Bearing: Description and Operation The rear hub and bearing assembly used on this vehicle is serviceable only as a complete assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort to repair it. The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are removable from the back of the rear hub/bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6896 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6897 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 5. Remove the 4 bolts attaching the hub/ bearing to the rear axle. CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6898 6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or equivalent and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or equivalent. Tighten bolt against Special Tool 8214-1 or equivalent. e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1 or equivalents. Removing Rear Hub/Bearing From Axle 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALL 1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation The temporary spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete details. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6916 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6917 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6918 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6919 WHEEL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6920 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6921 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6922 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6923 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. Technical Service Bulletin # 22-03-99 Date: 990423 Tires/Wheels - Smooth Road Vibration/Shake/Wobble. NUMBER: 22-03-99 GROUP: Wheels & Tires DATE: April 23, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994 SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: Smooth Road Vibration/Shake/Wobble OVERVIEW: This bulletin involves diagnosis and correction information for vehicles with a smooth road high-speed vibration or shake condition. Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph) is addressed by TSB 22-02-99. Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with 3.0L engine and 31TH transaxle is addressed by TSB 19-04-97. High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph). MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager (European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) EQUIPMENT REQUIRED: Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer (Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper POLICY: Information Only Diagnosis and Correction Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a hoist and inspect the following items: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6929 VISUAL INSPECTION Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road surface with all accessories turned off. Correct any obvious safety related items identified during the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components. If the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration problem is still present make the following checks: ^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the Service Manual. ^ If the vibration does not change while coasting then the problem may be caused by tires, wheels or suspension. ^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of rotating components (tires, wheels, half shafts, drums or rotors). ^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel assembly run out. ^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel assembly. ^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer to the Service Manual. ^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor, instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may be caused by high 1st order tire/wheel assembly excitation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6930 ON CAR TIRE/WHEEL ASSEMBLY RUNOUT After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s) return the vehicle to the customer. If the vibration is still present and it was determined that the vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure. Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of reducing runout. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6931 TIRE/WHEEL MATCH MOUNTING Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6932 WHEEL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6933 WHEEL BORE PILOT DIAMETERS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6934 HUB WHEEL PILOT DIAMETER Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6935 HUB WHEEL PILOT RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. > Page 6936 WHEEL MOUNTING SURFACE LATERAL RUNOUT Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6937 Wheels: Description and Operation Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use steel or aluminum drop center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps. Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and special wheel clamps for the alignment equipment. Do not use replacement parts of lesser quality or of a substitute design from the original equipment part. All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface. CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel lug nuts. This could adversely affect the safety and handling of your vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information Wheels: Testing and Inspection General Information Wheels must be replaced if they: - Have excessive run out - Are bent or dented - Leak air - Have damaged wheel lug holes Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed. Original equipment replacement wheels are available through the dealer. When obtaining replacement wheels from any other source, they must be equivalent in load carrying capacity. The wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match the original equipment wheels. CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety and handling of your vehicle. CAUTION: Replacement with used wheels is not recommended. The service history of the rim may have included severe treatment or very high mileage. The rim could fail without warning. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 6940 Wheels: Testing and Inspection Tire and Wheel Runout NOTE: Runout should always be measured off the vehicle and on a suitable balance machine. GENERAL INFORMATION Radial run out is the difference between the high and low points on the outer edge of the tire or wheel. Lateral run out is the total side-to-side wobble of the tire or wheel. Radial run out of more than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to shake. Lateral run out of more than 0.762 mm (0.030 inch) measured at the side of the tire as close to the tread as possible may cause the vehicle to shake. Sometimes radial run out can be reduced by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out to an acceptable level, the tire can be rotated on the wheel. (See Method 2). Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Fig. 2 Verify all wheel nuts are properly torqued. Fig. 3 Use run out gauge D-128-TR, or equivalent to determine run out. Relocate the wheel on the mounting studs, two studs over from the original position. Retighten wheel nuts until all are properly torqued. This will prevent brake distortion. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 6941 Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run out and proceed to Method 2. Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run out in both tire and wheel. Remove tire from wheel and remount wheel on hub in former position. Fig. 5 Check wheel radial run out. It should be no more than 0.5 mm (0.020 inch) for steel wheels and 0.38 mm (0.015 inch) for cast aluminum wheels. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing and Inspection > General Information > Page 6942 Fig. 6 Check wheel lateral run out. It should be no more than 0.8 mm (0.032 inch). If the point of greatest wheel radial run out is near the original chalk mark, remount the tire on the rim 180 degrees from its original position. Recheck the run out. If this does not reduce the run out to an acceptable level, replace the wheel and/or the tire. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance Wheels: Service and Repair Balance Balancing need is indicated by vibration of seats, floor pan, or steering wheel. The vibration will be noticed mostly when driving over 90 km/h (55 mph) on a smooth road. It is recommended that a two plane dynamic balancer be used when a wheel and tire assembly require balancing. Static balancing should be used only when a two plane balancer is not available. Off-vehicle tire and wheel balancing is recommended to be used on this vehicle. NOTE: If on vehicle equipment is being used to balance the tire/wheel assemblies, remove the opposite tire/wheel from the vehicle. Fig. 7 For static balancing, find the location of heavy spot on tire/wheel causing the imbalance. Counter balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer rim flange. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance > Page 6945 Fig. 8 For dynamic balancing, the balancing equipment is designed to indicate the location and amount of weight to be applied to both the inner and outer rim flanges. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Balance > Page 6946 Wheels: Service and Repair Installation Fig. 2 To install the wheel, first position it properly on the mounting surface of the hub using the hub pilot as a guide. All wheel nuts should be lightly tightened before progressively tightening them in the proper sequence. Then fully tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). Never use oil or grease on studs or nuts. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Lubricant Type Lubricant Type Wheel Bearing Grease NLGI GC rated automotive grease Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6950 Wheel Bearing: Description and Operation The rear hub and bearing assembly used on this vehicle is serviceable only as a complete assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort to repair it. The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are removable from the back of the rear hub/bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6951 Wheel Bearing: Testing and Inspection The rear hub and bearing assembly is designed for the life of the vehicle and should require no maintenance. The following procedure may be used for evaluation of bearing condition. With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from bearing is considered normal and should not require replacement of the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6952 Wheel Bearing: Service and Repair REMOVE 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and tire. 3. Remove brake drum from hub/bearing. 4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed sensor during removal and installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless the speed sensor is removed first. CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on the tone wheel will result in false ABS cycling and corrosion of the tone wheel. 5. Remove the 4 bolts attaching the hub/ bearing to the rear axle. CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in noise or failure of the bearing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6953 6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or equivalent and following procedure to press the hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should be against and supported by the axle plate when pressing the wheel bearing out of the axle. If Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the flashing from the hole until tool fits properly. d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or equivalent. Tighten bolt against Special Tool 8214-1 or equivalent. e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special Tool 8214-1 or equivalents. Removing Rear Hub/Bearing From Axle 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALL 1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing. Tighten the 4 bolts in a criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle. 4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm (105 inch lbs.). 6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications FRONT: To Hub Bearing Nut ............................................................................................................................. ............................................ 183 Nm (135 ft. lbs.) REAR: Stub Axle Nut ....................................................................................................................................... ............................................ 224 Nm (180 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Wheel Torque Sequence - Master Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6962 Wheel Fastener: Specifications Lug Nut Torque Lug Nut Torque .................................................................................................................................... ................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ........................................................... ........................................................................................................................................................... 19 mm Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6963 Wheel Fastener: Specifications Wheel Stud Size Mounting Stud Size ............................................................................................................................. ........................................................... M12 x 1.5 mm Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6964 Wheel Fastener: Description and Operation The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and must be replaced with equivalent parts. If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. Use the procedure and special tools shown in the service procedures section for the wheel mounting studs when replacing the wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle or the rear knuckle to replace the wheel attaching studs in the hub and bearing assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature bearing failure. REMOVE The following procedure and special tools shown MUST BE used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the steering knuckle to replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the vehicle. 3. Remove the front caliper assembly from the front steering knuckle assembly. Refer to Brakes and Traction Control for caliper removal procedure. 4. Remove front rotor from hub, by pulling it straight off wheel mounting studs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6967 5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the threads on the stud are even with end of lug nut. Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel stud. 6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel stud from flange. INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back over braking disc and align with caliper mounting holes on steering knuckle. Refer to Brakes and Traction Control for caliper installation procedure. Install the caliper adapter to steering knuckle attaching bolts and torque to 19 Nm (168 inch lbs.). 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 6. Lower vehicle to the ground. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 6968 Wheel Fastener: Service and Repair Rear CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. REMOVE The following procedure and special tools shown MUST be used when replacing wheel attaching studs. The hub and bearing assembly does not require removal from the rear axle for replacement of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum. 4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the threads on stud are even with end of lug nut. Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel stud. 5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly flange. Remove lug nut from stud and remove wheel stud from flange. INSTALL 1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on wheel stud, then install a wheel lug nut on stud with flat side of lug nut against washers. 2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud. 3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 5. Lower vehicle to the ground. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation SYSTEM OPERATION HVAC Mounted Switch HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend/Passenger Actuator Air Door Actuator / Motor: Description and Operation Blend/Passenger Actuator The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend/Passenger Actuator > Page 6978 Air Door Actuator / Motor: Description and Operation Driver Actuator The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will move towards the Heat position. When both Pins are high or when both Pins are low, the actuator will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test Air Door Actuator / Motor: Testing and Inspection Actuator Calibration/Diagnostics and Cool Down Test GENERAL INFORMATION If the HVAC control module is replaced, the Calibration Diagnostic and Cool-down tests will need to be performed. Once this group of tests have successfully passed, they can be performed individually. The engine must be running during the test to provide hot coolant for the heater, A/C compressor operation and to assure that the actuators are calibrated correctly The HVAC control module is capable of troubleshooting the system in approximately 120 seconds. If a condition is detected, an error code is displayed. The error code cannot be erased until the condition is repaired and the diagnostic test is performed. Check wire before replacing components. CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied. Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out of calibration. ACTUATOR CALIBRATION Radio Bezel And HVAC Control Radio Bezel And HVAC Control, Rear Blower Motor Switch And Zone Control Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cool-down test. DIAGNOSTICS During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cool-down test, after all repairs are Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6981 completed. COOL-DOWN TEST This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cool-down test will occur during Calibration test. Cool-down will not occur on Heater Only units. During the Cool-down test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes. Calibration/Cooldown LED Display Codes CALIBRATION COOL-DOWN LED DISPLAY CODES See table for definition of flashing LED's. If no problems are found, the control functions normally. CALIBRATION/DIAGNOSTICS TEST ENTRY To Initiate Tests: Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light) Results: All LED's will turn on for 5 Seconds - Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing. Cool-down test is running if A/C and RECIRC are alternately flashing. - Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit. - After all tests have passed, Calibration Diagnostics and Cool-down can be run separately COOL-DOWN TEST ENTRY To Initiate Tests: Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and A/C simultaneously for 5 Seconds NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct, operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6982 Results: All LED's will turn on for 5 Seconds - Cool-down Test is running when A/C and RECIRC. are alternately flashing. If A/C and RECIRC. are flashing simultaneously, Cool-down has failed. CALIBRATION DIAGNOSTICS AND COOL-DOWN ABORT Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons. - Cycling Ignition OFF and then ON. - Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cool-down was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cool-down test by LED's flashing simultaneously. EEPROM DATA Calibration Diagnostics, Cool-down Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information: To determine if Cool-down needs to run - For proper position of the Heater-A/C unit assembly doors ACTUATOR CALIBRATION AND DIAGNOSTICS NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6983 Air Door Actuator / Motor: Testing and Inspection Mode Actuator Background The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position. As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the mode door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Testing and Inspection > Page 6984 Air Door Actuator / Motor: Adjustments 1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4. Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master spline on PANEL door. Position actuator gear within cam wheel track. 5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door actuator to master spline on DEFROST door. Position actuator gear within cam wheel track. 6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cool-down test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement REMOVAL Side View Of HVAC With Actuators The air conditioning system can be equipped with either a standard, single blend-air door actuator, or it can be equipped with dual actuators. The dual system has separate blend-air controls. This allows for separate control of the driver's side air, and the passenger side air. 1. Remove the lower left side steering column cover. ABS Control Module 2. Remove ABS control module. 3. Remove blend-air actuator connector. Blend Air Actuator Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6987 4. Remove blend-air actuator. INSTALLATION 1. For installation, reverse the above procedures. 2. Perform the HVAC Control Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6988 Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement REMOVAL 1. Pull back on carpeting on the right lower floor. 2. Remove Recirc door actuator connector. Recirculation Door Actuator 3. Remove (3) mounting screws for Recirc actuator. 4. Remove Recirc actuator. 5. Disengage actuator linkage at Recirc door. 6. Remove actuator from vehicle. INSTALLATION 1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cool-down test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6989 Air Door Actuator / Motor: Service and Repair Front Heat A/C The content of this article reflects changes called for in TSB 26-06-98. REMOVAL 1. Remove the Instrument Panel. See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair ABS Control Module 2. Remove ABS control module. Mode Door Actuator Connector 3. Remove mode actuator connector. Mode Door Actuator Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6990 4. Remove mode door actuator. INSTALLATION 1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6991 Air Door Actuator / Motor: Service and Repair Rear Heat A/C REMOVAL 1. Remove A/C unit. 2. Place unit on bench. 3. Remove mode door actuator connector. 4. Remove mode door actuator mounting screws and remove actuator. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation SYSTEM OPERATION The air distribution ducts for the A/C, Heater, Defroster, and Second Seating Air Distribution are not serviceable in vehicle. The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts that feed the front door outlets for the first rear passenger(s) seating. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement Air Duct: Service and Repair Air Distribution Duct (A/C) Replacement REMOVAL Quarter Trim Panel 1. Remove quarter trim panel, D-pillar, and headliner. 2. Remove screws securing D-pillar duct to quarter panel. Pull duct up and away from unit. Rear Crossover Duct 3. Remove screws securing duct to rear header. Upper A/C Duct 4. Remove screws securing duct to right and left rails. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 6997 INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 6998 Air Duct: Service and Repair Air Distribution Duct (Heater) Replacement REMOVAL Quarter Trim Panel Rear Heat - A/C Unit 1. Remove quarter trim panel and D-pillar. 2. Remove screws securing lower heat duct to housing. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distribution Duct (A/C) Replacement > Page 6999 Air Duct: Service and Repair Side Window Demister Duct Replacement Left Side Demister Duct LEFT SIDE The LEFT side window demister duct is a two piece design. The left side has a long duct that attaches to an intermediate duct and then to the distribution housing. The duct is located on top of the instrument panel. To service the duct, remove the I/P cover and remove duct retainers/fasteners. Right Side Demister Duct RIGHT SIDE The demister duct on the right side is a one piece design. It is one long duct that attaches to the distribution housing. The duct is located on top of the instrument panel and it is not serviceable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 3. Remove sensor from vehicle. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis Blower Motor Noise/Vibration Diagnosis Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection > Flow of Diagnosis > Page 7007 Blower Motor: Component Tests and General Diagnostics VIBRATION AND/OR NOISE DIAGNOSIS The blower speed switch, in conjunction with the resistor block, supplies the blower motor with varied voltage. CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed from the heater A/C housing. Blower Motor Noise/Vibration Diagnosis Refer to the Blower Motor Vibration/Noise chart for diagnosis. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement Blower Motor: Service and Repair Blower Motor and Wheel Assembly Replacement REMOVAL 1. Remove glove box. Blower Motor Cover 2. Remove (4) hex head screws to blower motor cover. 3. Disconnect blower motor wiring. Wiring Grommet Feeding Wiring Through Housing 4. Remove grommet for wiring. Feed wiring through blower housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 7010 Blower Motor Screws 5. Remove mounting screws for blower motor. 6. Allow the blower assembly to drop down, and remove assembly from vehicle. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 7011 Blower Motor: Service and Repair Blower Motor Wheel Replacement The blower motor wheel is not serviced separately If the wheel needs to be replaced it is serviced as an assembly of the blower motor. For service procedure information, refer to Blower Motor Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Blower Motor and Wheel Assembly Replacement > Page 7012 Blower Motor: Service and Repair Rear Blower Motor Replacement REMOVAL 1. Remove the right quarter trim panel and D-pillar trim. Blower Motor 2. Remove (5) screws securing the blower motor housing to the rear of the HVAC housing (one screw located on evaporator cover). 3. Twist motor out of scroll housing. 4. Disconnect blower motor wiring connector. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 7017 Blower Motor Relay: Locations Rear Blower Relay Rear Blower Motor Relay This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 7020 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation Blower Motor Resistor: Description and Operation SYSTEM OPERATION The rear blower motor resistor is not serviceable separately. The resistor is integral to the blower motor. If resistor is faulty, it is necessary to replace the complete blower motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 7024 Blower Motor Resistor: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate negative battery cable. Resistor Block Location 3. Locate and remove the wire connector from the blower resistor block. Block is located at the back of the engine compartment on the passenger side of the vehicle under the wiper module. NOTE: It may not necessary to remove the wiper module to access the resistor block. Resistor Block Removal 4. Using a long flat blade screwdriver, gently push in on drivers side of resistor. Be careful to catch the inner release tang and gently pry outward. WARNING: THE RESISTOR BLOCK MAY BE HOT. DO NOT ATTEMPT TO SERVICE THE RESISTOR BLOCK IF THE SYSTEM HAS BEEN RUNNING RECENTLY. LET THE SYSTEM COOL DOWN BEFORE REPAIRS ARE INITIATED. 5. Remove resistor block by inserting a flat blade pry tool on the side of the resistor block and pushing inward. Two guide lines are shown on the right hand edge of the resistor block to help guide the blade position. This will release the clips on the side of the resistor block. Pull resistor block out. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Page 7025 INSTALLATION - For installation, reverse the above procedures. Make sure the "TOP" lettering is on the top of the resistor. The coils on the Resistor Block should not be contacting one another. Before installation, gently separate the coils (with fingers only) if one coil is contacting another. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION The rear blower speed switch controls the rear blower with the choice of low and high speeds. When the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Clutch Air Gap ..................................................................................................................................... ........................... 0.41 - 0.79 mm (0.016 - 0.031 in.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7033 Compressor Clutch: Service and Repair REMOVAL and INSTALLATION After a new clutch has been installed, check the voltage and amperage to the clutch (determine it to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control Module. It is located in the engine compartment outboard of the battery. If the compressor clutch does not engage verify refrigerant charge. If the compressor clutch still does not engage check for battery voltage at the pressure transducer located on the liquid line. If voltage is not detected, refer to Powertrain Management/Computer and Control Systems/Powertrain Diagnostic Procedures for diagnostic information. If voltage is detected at the pressure transducer connect pressure transducer and check for battery voltage between the compressor clutch connector terminals. If voltage is detected, perform A/C Clutch Coil Tests. Tests 1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch. 3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. 4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fuse. 5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21 degree Celsius (70 degree Fahrenheit). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. 6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7037 Compressor Clutch Coil: Service and Repair REMOVAL Compressor Shaft Bolt And Clutch Plate 1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal. CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front plate as this may damage the front plate assembly. Clutch Plate And Shims 2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7038 Removing Pulley Snap Ring 3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off of compressor. 4. Remove coil wire clip screw and wire harness. Clutch Coil Snap Ring 5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced. 7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has contaminated the faces of the pulley or front plate, they should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly. CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part. This will result in clutch slippage due to insufficient contact area. INSTALLATION 1. Align pin in back of field coil with hole in compressor end housing, and position field coil into place. Make sure that lead wires are properly routed, and fasten with the wire clip screw. 2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing outward. Also both snap ring eyelets must be to the right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the groove. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7039 CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe damage to the front face of the compressor. Installing Pulley Assembly 3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the friction surface. CAUTION: Do not mar the pulley frictional surface. 4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the snap ring to make sure it is properly seated in the groove. 5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 1 mm (0.040 in.) thick, on the shaft against the shoulder. 6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s), measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or subtract shims until desired air gap is obtained. 8. Install compressor shaft bolt. Tighten to 17.5 +/-2 N.m (155 +/- 20 in. lbs.). NOTE: Shims may compress afier tightening shaft nut. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 7044 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser Condenser HVAC: Service and Repair Front A/C Condenser WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL 1. Recover A/C system refrigerant. Liquid Line 2. Remove liquid line at filter-drier. Filter Drier 3. Remove (2) bolts attaching filter-drier to radiator module. 4. Remove upper radiator crossmember. 5. Tilt radiator rearward. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser > Page 7050 Upper Discharge Line 6. Remove upper discharge line at condenser. 7. Through fascia, remove lower liquid line from filter-drier. 8. Remove (2) lower condenser mounting bolts. 9. Remove (2) upper mounting bolts. Condenser Removal 10. Remove condenser from vehicle. INSTALLATION NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation. 1. Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved wax-free refrigerant oil. Then, reverse the above procedures. 2. Torque the following components to specifications: - Liquid line at filter/drier - 45 in. lbs. +/- 10. - Upper discharge line at condenser - 180 in. lbs +/- 20 - Lower liquid line to condenser - 180 in. lbs +/- 20. - (2) lower, condenser mounting bolts - 45 in. lbs +/- 10. - (2) upper, condenser mounting bolts - 45 in. lbs +/- 10. 3. Evacuate and charge system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Front A/C Condenser > Page 7051 Condenser HVAC: Service and Repair Rear A/C Auxiliary Condenser In vehicles equipped with rear heater and air conditioning, it will be equipped with an auxiliary condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator. Both condenser must be removed as an assembly and then separated. WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. NOTE: Special effort must be used to keep all R-134a system components moisture-tree. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY removal and installation. REMOVAL 1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1) bolt to liquid line on auxiliary condenser. Rear Heat - A/C Auxiliary Condenser 3. Remove (4) attaching bolts and separate auxiliary from primary condenser. INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces with approved wax free refrigerant oil. Then, reverse the above procedures. 2. Evacuate and recharge system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations HVAC Control Module The control module is included in the A/C control head located on the instrument panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7055 Control Assembly: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7056 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7057 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7058 Control Assembly: Description and Operation HVAC Control Module HVAC Control Module The HVAC control module regulates the operation of the various actuator motors. The actuator motors are used to move the mode, blend-air, and Recirculation doors. The control module is included in the A/C control head located on the instrument panel. The control head includes the blower speed switch, rear wiper and washer operation, front & rear window defogger, recirculation door operation, and A/C compressor operation if equipped. NOTE: The Recirculation function on the HVAC control module automatically defaults to the OFF position after a ignition key cycle. To reactivate the Recirculation function, the Recirculation button must be repressed. NOTE: The rear blower speed switch is serviced separately from the control head. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit Control Assembly: Testing and Inspection Calibration -- May Be Needed After Replacing Control Unit Actuator Calibration/Diagnostics and Cool-down Test GENERAL INFORMATION If the Heating Ventilation and Air Conditioning (HVAC) control module is replaced, the Calibration Diagnostic and Cool-down tests will need to be performed. Once this group of tests have successfully passed, they can be performed individually. The engine must be running during the test to provide hot coolant for the heater, A/C compressor operation and to assure that the actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the system in approximately 120 seconds. If a condition is detected, an error code is displayed. The error code cannot be erased until the condition is repaired and the diagnostic test is performed. Check wiring before replacing components. CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied. Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out of calibration. Radio Bezel and HVAC Control Radio Bezel and HVAC Control w/Rear Blower and Zone Control ACTUATOR CALIBRATION Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the actuators, HVAC control module and its Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7061 linkages. In vehicle calibration can be entered from the control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cool-down test. DIAGNOSTICS During the Actuator calibration, diagnostics are performed on the actuators and evaporator temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously showing that a failure has occurred. The control will not indicate the fail code, but only that a failure had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the Calibration Diagnostic and Cool-down test, after all repairs are completed. COOL-DOWN TEST This test has been designed for performance testing of the A/C system at the manufacturing facility. If the HVAC control module is replaced, the Cool-down test will occur during Calibration test. During the Cool-down test the control will monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator temperature down a predetermined minimum amount in less than 2 minutes. NOTE: Cool-down will not occur on Heater Only units. CALIBRATION/COOL-DOWN LED DISPLAY CODES Calibration/Cooldown Test LED's NOTE: See chart for definition of flashing LED's. If no problems are found, the control functions normally. CALIBRATION/DIAGNOSTICS TEST ENTRY TO INITIATE TESTS: - Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light) RESULTS: - All LED's will turn on for 5 Seconds - Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing. Cool-down test is running if A/C and RECIRC are alternately flashing. - Acceptable result is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7062 - After all tests have passed, Calibration Diagnostics and Cool-down can be run separately. COOL DOWN TEST ENTRY NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct, operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test. TO INITIATE TESTS: - Set Blower motor ON HIGH - Set Mode position to Panel - Open all A/C outlets - Set Temperature to Cold (Both slide pots if equipped) - Depress WASH and A/C simultaneously for 5 Seconds RESULTS: - All LED's will turn on for 5 Seconds - Cool-down Test is running when A/C and RECIRC are alternately flashing. If A/C and RECIRC are flashing simultaneously, Cool-down has failed. CALIBRATION DIAGNOSTICS AND COOL-DOWN ABORT Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons. - Cycling Ignition OFF and then ON. - Control will automatically abort after 15 minutes from the time Calibration Diagnostics and Cool-down was entered. The HVAC control module will return to normal operation or may indicate unsuccessful Calibration Diagnostics or Cool-down test by LED's flashing simultaneously. EEPROM DATA Calibration Diagnostics, Cool-down Status and evaporator temperature Fin Sensor values are stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control module uses this information: To determine if Cool-down needs to run - For proper position of the Heater-A/C unit assembly doors ACTUATOR CALIBRATION AND DIAGNOSTICS NOTE: Do not run actuators unless they are properly mounted on the HVAC control module. Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as actuator travel falling within their minimum and maximum limits. Blend/Passenger Actuator Background The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Driver Actuator Background The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will move towards the Heat position. When both Pins are high or when both Pins are low, the actuator will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the temperature door. Mode Actuator Background The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position. As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is necessary for the correct positioning of the mode door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7063 FAIL CODES/LEVEL DISPLAY Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LED's flashing in sequence. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you will cycle back to Level 1. Failure Code Levels -- Wipe Button LED Level Display 1 Fail Codes 2 Mode Potentiometer Test 3 Blend/Pass. Potentiometer Test 4 Evaporator Probe (A/C and Zone Units Only) 5 Driver Potentiometer (Zone Units Only) Level 1 Failure Codes -- Intermittent Wipe Button LED Code Definition 0 Passed ALL Tests 1 Mode Actuator Did Not Reach Defrost Position 2 Mode Actuator Did Not Reach Panel Position 3 Blend/Pass Actuator Did Not Reach Cold Stop 4 Blend/Pass Actuator Did Not Reach Heat Stop 5 Evaporator Probe Open 6 Evaporator Probe Shorted 7 Driver Actuator Did Not Reach Cold Stop 8 Zone/Driver Actuator Did Not Reach Heat Stop 9 Control Head Internal Failure NOTE: If the Control is a Heater Only you will only cycle from Levels 1 to 3. TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS A/C Units The Temperature and Mode Potentiometer can be tested after calibration is complete by pressing the WASH button and cycling to Levels 2, 3 or 5 as displayed by the REAR WIPER LED. INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved from one end to the other. Heater Only Units On Heater Only units you can only cycle to Levels 2 and 3. In each individual test the INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved from one end to the other. EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. Display Sequence is as follows: REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one's digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cool-down test is exited. A/C and Recirc LED's Flashing Simultaneously FAILED COOL-DOWN TEST. 1. Determine if the refrigerant system is operating correctly: - Check the outlet air temperature - Feel the compressor suction plumbing, is it hot? 2. If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cool-down test. 3. If system does not seem to be operating correctly, perform diagnostics for poor performance: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7064 - Low refrigerant charge - No charge - Compressor not operating COOL-DOWN TEST Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7°C (20°F). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7°C (20°F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cool-down test. WON'T PASS COOL-DOWN TEST If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cool-down test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cool-down test manually with a pocket thermometer. The outlet air temperature must drop at least 7°C (20°F) within two minutes. If the vehicle passes with the manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cool-down test. Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will drop the temperature 7°C (20°F) in two minutes. If the Evaporator Probe is found to be faulty, check that the sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK, replace the evaporator probe. Once the repairs are completed, repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Not Flashing The system has passed calibration. Press the Rear Wiper button to exit calibration. Rear Wiper LED Flashing Once, Int. LED Flashing Once THE MODE ACTUATOR DID NOT REACH DEFROST POSITION 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the defrost to panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Twice THE MODE DOOR DID NOT REACH PANEL POSITION 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from panel to defrost position, and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to Step 3. If not OK, repair as necessary 3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Three Times THE MAIN TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH COLD STOP. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the cold to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to Step 4 If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Four Times THE MAIN TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH HOT STOP. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from hot to cold position and check Pin 5 voltage it should change from 3.5 - 4.5 volts 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary 4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7065 Rear Wiper LED Flashing Once, Int. LED Flashing Five Times THE EVAPORATOR PROBE IS OPEN. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If not OK, if greater than 4.75 volts check for loose or corroded connector, open circuit and repair as necessary. 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Six Times THE EVAPORATOR PROBE IS SHORTED. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts, If OK, go to Step 2. If less than 0.1 volts, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator Probe 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Seven Times THE DRIVER'S TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH COLD STOP. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from cold to the hot position, check Pin 4 voltage it should changeover 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding doors, if door are binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Eight Times THE DRIVER'S TEMPERATURE ACTUATOR ON A ZONE SYSTEM DUD NOT REACH HOT STOP. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from hot to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Rear Wiper LED Flashing Once, Int. LED Flashing Nine Times THE HVAC CONTROL MODULE, HAS AN INTERNAL FAILURE. 1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Failure Codes/Level Display Wipe Button LED Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7066 Level 1 - Failure Code Values (Intermittent Wipe Button LED) Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LED's flashing in the sequence indicated below. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you will cycle back to Level 1. If the Control is a Heater Only you will only cycle from Levels 1 to 3. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7067 Control Assembly: Testing and Inspection HVAC Control Diagnostic Conditions After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing. The system has passed calibration. Press the Rear Wiper button to exit calibration. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing once. The mode actuator did not reach defrost position. 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the defrost to panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing twice. The mode actuator did not reach panel position. 1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from panel to defrost position, and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing three times. The main temperature actuator/passenger temperature actuator on a zone system did not reach cold stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from the cold to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main temperature actuator/passenger temperature actuator on a zone system did not reach hot stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC control from hot to cold position and check Pin 5 voltage it should change from 3.5-4.5 volts 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if the gear pins are in the correct track on cain or if they are binding. If OK, go to Step 4. If not OK, repair as necessary 4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing five times. The evaporator probe is open. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If not OK, if greater than 4.75 volts check for loose or corroded connector, open circuit and repair as necessary 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory Then repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The evaporator probe is shorted. 1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If OK, go to Step 2. If less than 0.1 volts, check for loose or corroded connector, open or shorted circuit and repair as necessary. 2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator Probe 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's light to remove fault code from memory. Then repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing seven times. The Driver's temperature actuator on a zone system did not reach cold stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7068 cold to the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary. 4. Check for binding doors, if door are binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Driver's temperature actuator on a zone system did not reach hot stop. 1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC control from hot to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as necessary. 3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are binding. If OK, go to Step 4. If not OK, repair as necessary 4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC control module, has a internal failure. 1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. After calibration and testing the NC and RECIRC LED flashing simultaneously. Failed Cool-down test. 1. Determine if the refrigerant system is operating correctly: - Check the outlet air temperature - Feel the compressor suction plumbing, is it hot? 2. If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cool-down test. 3. If system does not seem to be operating correctly, perform diagnostics for poor performance: - Low refrigerant charge - No charge - Compressor not operating Verify that the test was done with the evaporator at room temperature. The test consists of starting the compressor and measuring the time it takes for the evaporator temperature to fall 7 degree Celsius (20 degree Fahrenheit). If the compressor has been running, the evaporator is cold already and will not be capable of falling 7 degree Celsius (20 degree Fahrenheit). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cool-down test. If refrigerant system is performing properly and the system will not pass test. Repeat the Calibration Diagnostic and Cool-down test to determine if the evaporator temperature FIN sensor has developed an open or a short circuit. If the HVAC control module still passes Calibration test, verify Cool-down test manually with a pocket thermometer. The outlet air temperature must drop at least 7 degree Celsius (20 degree Fahrenheit) within two minutes. If the vehicle passes with the manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and repeat the Cool-down test. Ensure the evaporator is at room temperature before starting test. Check if evaporator probe will drop the temperature 7 degree Celsius (20 degree Fahrenheit) in two minutes. If the Evaporator Probe is found to be faulty, check that the sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK, replace the evaporator probe. Once the repairs are completed, repeat the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement Control Assembly: Service and Repair Heater-A/C Control Lamp Replacement HVAC Control Lamps REMOVAL 1. Remove radio bezel and HVAC Control. 2. Remove rear cover from HVAC control. 3. Rotate bulb socket counter clockwise one quarter turn. 4. Pull bulb socket from HVAC. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 7071 Control Assembly: Service and Repair Radio Bezel and HVAC Control Replacement REMOVAL 1. Remove convenience bin-cup holder. 2. Insert the trim stick (special tool #C-4755) between access cover and radio bezel, above convenience bin-cup holder. Convenience Bin Access Cover 3. Carefully pry the access cover from the instrument panel. 4. Separate the access cover from the vehicle. 5. Remove convenience bin-cup holder track. Radio Bezel And HVAC Control 6. Remove the attaching screws holding bottom of the bezel to instrument panel. 7. Remove the attaching screws holding top of the bezel to the instrument panel. 8. Remove the bezel from the instrument panel. 9. Disconnect the wire connector from back of the rear blower switch, if equipped. 10. Disconnect the wire connector from the back of the HVAC Control. 11. Remove the bezel. INSTALLATION 1. Hold the radio bezel up and connect the wire connector into the back of the HVAC control. 2. Connect the wire connector into back of the rear blower switch, if equipped. 3. Place the radio bezel in position on the instrument panel. 4. Install screws to hold the top of radio bezel to instrument panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 7072 5. Install screws to the hold bottom of the radio bezel to the instrument panel. 6. Install the access cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 7073 Control Assembly: Service and Repair Rear Heater-A/C Switch Lamp Replacement Rear Heater - A/C Switch Lamp Bulb REMOVAL 1. Remove radio bezel HVAC Control. 2. Rotate bulb socket counter clockwise one quarter. 3. Pull bulb socket from switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 7074 Control Assembly: Service and Repair Rear Heater-A/C Switch Replacement Rear Heater - A/C Switch REMOVAL 1. Remove radio bezel and HVAC Control. 2. Remove screw holding rear heater - A/C switch to radio bezel HVAC Control. 3. Disengage hook holding bottom of switch to radio bezel HVAC Control. 4. Remove switch from radio bezel HVAC Control. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Heater-A/C Control Lamp Replacement > Page 7075 Control Assembly: Service and Repair Sticking HVAC Control Module Push Buttons Sticking HVAC Control Module Push Buttons To service HVAC control module push buttons that are sticking, spray between the buttons with Mopar MP-50. The MP-50 is a all purpose lubricant for mechanical and electrical uses. After spraying around the push buttons wipe any excess off the radio bezel and HVAC control module push buttons. Operate the buttons to ensure that they are operating freely. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7084 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7085 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7086 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7087 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7093 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7094 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7095 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7096 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Evaporator Case: Service and Repair Evaporator Housing Disassembly and Assembly DISASSEMBLY 1. Place HVAC unit assembly on workbench. Distribution Housing 2. Remove distribution housing mounting screws. Blower Motor Cover 3. Remove blower motor cover. Blower Motor Grommet 4. Remove blower motor wiring grommet and feed wiring through blower housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7099 Blower Motor Screws Blower Motor 5. Remove blower motor screws. Remove blower motor from housing. Recirculation Door Cover 6. Remove recirculation door cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7100 RECIRC Door 7. Remove Recirc. door. HVAC Cover 8. Remove screws around the perimeter of the upper HVAC housing. CAUTION: Do not damage the insulation barrier surrounding the evaporator. Evaporator 9. Carefully pull up on evaporator and remove from housing. 10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new evaporator before installing. ASSEMBLY 1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7101 Evaporator Case: Service and Repair Evaporator Housing Removal and Installation REMOVAL WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING. 1. Set parking brake. 2. Disconnect battery negative cable. A/C Service Ports 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper Control Module/Service and Repair 5. Pinch off rear heater lines if equipped. Heater Hoses 6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7102 Expansion Valve Plate 7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 9. Remove heater ducts. 10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel. HVAC Bolt Up 11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12 Disconnect the HVAC housing wiring harness. 13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. INSTALLATION 1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7103 Evaporator Case: Service and Repair Rear Evaporator Removal and Installation NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll. Evaporator Cover 5. Remove evaporator cover. Expansion Valve 6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7104 Evaporator Removal 7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 8. Remove and discard the O-rings between the plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to prevent contamination. 10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil from the removed evaporator. INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 ± 3 NM (100 ± 30 inch pounds) torque. CAUTION: Do not damage the evaporator insulation liner during installation. 3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 +/- 3 N.m (200 +/- 30 inch pounds) torque. 6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system, and perform the performance test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications Evaporator Core: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core Evaporator Core: Service and Repair Front Evaporator Core REMOVAL 1. Set parking brake. 2. Disconnect battery negative cable. A/C Service Ports 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper Control Module/Service and Repair 5. Pinch off rear heater lines if equipped. Heater Hoses 6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7110 Expansion Valve Plate 7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 9. Remove heater ducts. 10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel. HVAC Bolt Up 11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12 Disconnect the HVAC housing wiring harness. 13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. Evaporator Core Removal 1. Place HVAC unit assembly on workbench. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7111 Distribution Housing 2. Remove distribution housing mounting screws. Blower Motor Cover 3. Remove blower motor cover. Blower Motor Grommet 4. Remove blower motor wiring grommet and feed wiring through blower housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7112 Blower Motor Screws Blower Motor 5. Remove blower motor screws. Remove blower motor from housing. Recirculation Door Cover 6. Remove recirculation door cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7113 Recirculation Door 7. Remove recirculation door. HVAC Cover 8. Remove screws around the perimeter of the upper HVAC housing. CAUTION: Do not damage the insulation barrier surrounding the evaporator. Evaporator 9. Carefully pull up on evaporator and remove from housing. 10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7114 evaporator before installing. Note: For reassembly of the evaporator housing, reverse the above procedures. - Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection INSTALLATION 1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic and Cool-down test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7115 Evaporator Core: Service and Repair Rear Evaporator Core NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll. Evaporator Cover 5. Remove evaporator cover. Expansion Valve 6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front Evaporator Core > Page 7116 Evaporator Removal 7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to prevent contamination. 10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil from the removed evaporator. INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30 inch pounds) torque. CAUTION: Do not damage the evaporator insulation liner during installation. 3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds) torque. 6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system, and perform the performance test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7125 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7126 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7127 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7128 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7134 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7135 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7136 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7137 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Page 7138 Evaporator Drain Tube: Description and Operation SYSTEM OPERATION Condensate Drain Condensation from the evaporator housing is drained through the dash panel and on to the ground. This drain must be kept open to prevent water from collecting in the bottom of the housing. If the drain is blocked condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. - Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one's digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cool-down test is exited. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 7142 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION - For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and Inspection Expansion Valve: Testing and Inspection NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. Tests NOTE: Expansion valve tests should be performed after compressor tests. Review Safety Precautions and Warnings. The work area and vehicle temperature must be 21 degree Fahrenheit to 27 degree Celsius (70 degree Fahrenheit to 85 degree Fahrenheit). To test the expansion valve: NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply facilities. CO2 is also available from companies which service and sell fire extinguishers. 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment. 3. Set heater A/C control to A/C, full heat, FLOOR, and high blower. 4. Start the engine and allow to idle (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator. 5. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi). Suction (low pressure) gauge should read 140 kPa to 207 kPa (20 psi to 30 psi). If system cannot achieve proper pressure readings, replace the expansion valve. If pressure is correct, proceed with test. WARNING: PROTECT SKIN AND EVES FROM CONTACTING CO2 PERSONAL INJURY CAN RESULT. 6. If suction side low pressure is within specified range, freeze the expansion valve control head for 30 seconds. Use a super cold substance (liquid CO2). Do not spray R-134a or R-12 Refrigerant on the expansion valve for this test. Suction side low pressure should drop by 10 psi. If not, replace expansion valve. 7. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not, replace expansion valve. 8. When expansion valve test is complete, test A/C overall performance. Remove all test equipment before returning vehicle to use. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation Expansion Valve: Service and Repair Expansion Valve Removal and Installation WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Disconnect generator field wire connector. 6. Push generator forward. 7. Remove ground wire at dash panel. A/C Refrigerant Line Plate 8. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 9. Remove the stud from the expansion valve. 10. Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front of the vehicle. Use care not to scratch the expansion valve sealing surfaces with pilot tubes. 11. Cover the openings to prevent contamination. 12. Remove two screws securing the expansion valve to the evaporator sealing plate. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 7148 Expansion Valve Removal 13. Carefully remove expansion valve. 14. Remove the old O-rings. INSTALLATION 1. Ensure old O-rings are removed. Install new O-rings on the refrigerant lines and evaporator sealing plate. 2. Hand-start the stud into the expansion valve and torque to 7 - 11 N.m (64 - 96 in. lbs.). 3. Carefully install the expansion valve to the sealing plate. Install the two screws and tighten 8 to 14 N.m (70 to 130 in. lbs.) torque. 4. Carefully install the refrigerant lines and sealing plate to the expansion valve. Install the nut and tighten 20 to 26 N.m (170 to 230 in. lbs.) torque. 5. Install the ground wire at dash panel. 6. Pull generator back into the proper position for bracket mounting. 7. Install generator field wire connector. 8. Install the upper generator bracket. 9. Install accessory drive belt. 10. Evacuate and recharge system. 11. After expansion valve is installed, the system is charged, and leaks have checked repeat the A/C performance check. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 7149 Expansion Valve: Service and Repair Evaporator Core and Expansion Valve Replacement NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3. Remove rear A/C unit. 4. Remove blower scroll. Evaporator Cover 5. Remove evaporator cover. Expansion Valve 6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Expansion Valve Removal and Installation > Page 7150 Evaporator Removal 7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 8. Remove and discard the O-rings between the plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to prevent contamination. 10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil from the removed evaporator. INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch the sealing surface). Install two screws and tighten to 11 +/- 3 N.m (100 +/30 inch pounds) torque. CAUTION: Do not damage the evaporator insulation liner during installation. 3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the sealing surfaces with the plumbing extension tube pilots. 4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the plumbing plate into the unit sealing plate. Tighten bolts to 23 +/- 3 N.m (200 +/- 30 inch pounds) torque. 6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system, and perform the performance test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core Heater Core: Service and Repair Front Heater Core REMOVAL 1. Drain coolant system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 2. Remove left side lower column cover. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Remove steering column assembly. See: Steering and Suspension/Steering/Steering Column/Service and Repair ABS Module 4. Remove ABS module, bracket and wiring. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair Interconnect And Bracket 5. Remove I/P to body harness interconnect and bracket. Lower Silencer Boot Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 7155 6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood. Heater Core Plate And Tubes 8. Remove heater core cover. Insert a small amount of towels under the heater core tubes. Remove heater core plate and tubes. Depress Clips 9. Depress heater core retaining clips. Accelerator Pedal 10. Pull up on accelerator pedal and slide heater core past. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 7156 Brake Pedal 11. Depress brake pedal and remove heater core from HVAC housing. INSTALLATION - For installation, reverse the above procedures. Install screws to retain heater core in housing. Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 N.m (27 ± 9 in. lbs.) torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core > Page 7157 Heater Core: Service and Repair Rear Heater Core REMOVAL 1. Remove the lower right quarter trim panel. Heater Core Lines 2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4. Carefully pull the heater core and tubes up and straight out of the unit. INSTALLATION Filling Heater Core - For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be used: Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor on HIGH - Discharge air temperature, measured at the dual register located on the C-pillar base, is between 57 degree Celsius to 62 degree Celsius (135 degree and 145 degree Fahrenheit). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations Heater Hose: Locations Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations > Page 7161 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses Heater Hose: Service and Repair Heater Hoses REMOVAL NOTE: Review Safety Precautions and Warnings before proceeding with this operation. 1. Drain engine cooling system. Upper Heater Hose Lower Heater Hose 2. Loosen clamps at each end of heater hose to be removed. CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive force. Heater core may become damaged and leak engine coolant. 3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the hose will not come off, slice the hose at the connector nipple and peel off heater hose. This method will require heater hose replacement. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 7164 Heater Hose: Service and Repair Underbody Plumbing Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hoses > Page 7165 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. For more information, refer to Heater core/ Service and Repair. See: Heater Core/Service and Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation SYSTEM OPERATION A/C Pressure Transducer A/C Pressure Transducer The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system. The transducer is located on the liquid line. The pressure transducer turns off the voltage to the compressor clutch coil when refrigerant gas pressure drops to levels that could damage the compressor. The transducer also is used to adjust condenser fan speeds and will turn off compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated unit. It must be replaced if defective. 0-ring replacement is required whenever the pressure transducer is serviced. Be sure to use the 0-ring specified for the transducer. Compressor High-Pressure Relief Valve The High Pressure Relief Valve prevents damage to the air conditioning system if excessive pressure develops. Excessive pressure can be caused by condenser air flow blockage, refrigerant overcharge, or air and moisture in the system. The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system pressure and then reseats itself. The majority of the refrigerant is conserved in the system. The valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi). If a valve has vented a small amount of refrigerant, it does not necessarily mean the valve is defective. The High Pressure Relief Valve is located on the compressor manifold at the discharge passage. NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 7169 High Pressure Safety Valve HVAC: Testing and Inspection The work area temperature must not be below 10 degree Celsius (50 degree Fahrenheit) to test the compressor clutch circuit. Before starting to test the transducer ensure that the wire connector is clean of corrosion and connected properly. 1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install scan tool (DRB): - Go to main menu - Select stand alone scan tool (DRB) - Select refer to the proper year diagnostics - Select climate control - Select sensor display - Select A/C high side volts For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition and will not allow the compressor to cycle. A/C Pressure Transducer Voltage Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 7170 High Pressure Safety Valve HVAC: Service and Repair REMOVAL 1. Disconnect the wire connector at the pressure transducer. A/C Pressure Transducer Removal 2. Using an open end wrench, remove the transducer from the liquid line. INSTALLATION 1. Replace transducer O-ring. 2. For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > A/C Suction/Discharge Line - Service Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service NUMBER: 24-14-99 GROUP: Heating & A/C DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: A/C Suction And/Or Discharge Line Service MODELS: 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are torqued to 40 ft. lbs. (54 Nm). The root cause of A/C suction and/or discharge line cracking at or near the compressor may be related to the compressor being improperly secured to the engine. Excessive vibration may result if the compressor attaching bolts are not properly torqued. This vibration will eventually crack the aluminum tubing of the A/C lines and/or compressor mounting ears. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7175 Hose/Line HVAC: Locations Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7176 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7177 Hose/Line HVAC: Description and Operation SYSTEM OPERATION Rear Heater And A/C Lines Front Lines Connected To Rear Lines Rear Heater Hose Connection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7178 Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is dean of any contaminations that can get in to the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement REMOVAL 1. Recover A/C system refrigerant. Compressor Discharge Line 2. Remove discharge line mounting nut at compressor. Condenser Discharge Line 3. Remove discharge line at the top fitting on the condenser. INSTALLATION 1. For installation, reverse the above procedures. Replace all O-rings. Torque discharge line at condenser bolt to 180 in. lbs. +/- 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC Control Calibration Diagnostic and Cool-down test. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 7181 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9. Cover the openings to prevent contamination. 10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line mounting plate at filter-drier. Remove liquid line from filter-drier. It may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece assembly 13. Remove the old O-rings. INSTALLATION - For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 7182 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel. A/C Refrigerant Line Plate 6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve. Expansion Valve Stud And Mounting Screws 7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve. Suction Line At Compressor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 7183 9. Remove suction line mounting nut at compressor. 10. Remove suction line mounting bracket. 11. Remove suction line. INSTALLATION - For installation, reverse the above procedures. - Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque. - Install new O-rings. - Install two-piece line in place of original part. - Assemble line halves after it is installed on vehicle. - Evacuate and recharge A/C system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 7184 Hose/Line HVAC: Service and Repair Refrigerant Line Replacement Rear Air Conditioning Lines Rear Heater And A/C Lines Front Lines Connected To Rear Lines Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 7185 Rear Heater Hose Connection Rear Heater Hose Quick Connects Rear A/C Block Connection The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system. For more information, refer to Housing Assembly HVAC/ Service and Repair. See: Housing Assembly HVAC/Service and Repair Rear Heater A/C Air Outlets REMOVAL - Separate barrel from bezel by pulling outward. INSTALLATION - For installation, push the outlet firmly into the opening until it locks into place. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly DISASSEMBLY 1. Place HVAC unit assembly on workbench. Distribution Housing 2. Remove distribution housing mounting screws. Blower Motor Cover 3. Remove blower motor cover. Blower Motor Grommet 4. Remove blower motor wiring grommet and feed wiring through blower housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7190 Blower Motor Screws Blower Motor 5. Remove blower motor screws. Remove blower motor from housing. Recirculation Door Cover 6. Remove recirculation door cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7191 Recirculation Door 7. Remove Recirc door. HVAC Cover 8. Remove screws around the pen meter of the upper HVAC housing. CAUTION: Do not damage the insulation barrier surrounding the evaporator. Evaporator 9. Carefully pull up on evaporator and remove from housing. 10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of the same amount (ND8 PAG) to the new evaporator before installing. Use SP 10 PAG oil for 2.5L diesel and 2.0L gasoline engine vehicles. ASSEMBLY 1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7192 Housing Assembly HVAC: Service and Repair Distribution Housing Disassembly and Assembly DISASSEMBLY Distribution Housing 1. Place distribution housing on workbench. Heater Core Cover 2. Remove heater core cover. Heater Core Tube Plate Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7193 Plate Removal 3. Remove heater core tube plate. Heater Core Tube Removal 4. Remove heater core tubes. 5. Depress heater core retaining clips at housing. When reinstalling core use screws to fasten the heater core to the housing. 6. Slide heater core out of the housing. Driver's Zone Actuator 7. Remove driver's zone actuator from distribution housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7194 Passenger Zone Actuator 8. Remove passenger zone actuator from distribution housing. Distribution Housing Blend Air Door Drive Gear 9. Using a long thin flat blade tool, insert tool through blend-air opening on top of distribution housing. Depress clip retaining the driver's blend-air door drive gear. Pull out on gear and remove from the housing. 10. Remove mode door motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7195 Panel Door Gear 11. Remove Panel door actuator gear. Defrost Door Gear 12. Remove defrost door actuator gear. Cam Wheel 13. Remove cam wheel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7196 Heat Door Gear 14. Remove heat door actuator gear. Distribution Housing 15. Remove distribution housing lower cover screws. Distribution Housing Half Screws 16. Remove distribution housing half screws. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7197 Front Cover View Of Zone Control Doors 17. Remove distribution housing front cove. 18. Remove weather-strip at fresh-air vent. Distribution Housing Halves 19. Separate housing halves. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7198 Defrost Door 20. Pull up on separator plate and remove defrost door. Panel Door 21. Remove upper half Panel door. Floor Door 22. Remove upper half of Floor door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7199 Blend Air Door 23. Remove upper half of the blend-air door (slide off of shaft). Separator Plate 24. Remove separator plate from distribution housing. Lower Blend Air Door 25. Remove lower half of the blend-air door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7200 Lower Panel Door 26. Remove lower half of the Panel door. Lower Floor Door 27. Remove lower half of the Floor door. ASSEMBLY - For reassembly of the distribution housing, reverse the above procedures. - To reassemble the distribution housing actuator gears an assembly procedure of the gears and cam is necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7201 Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation REMOVAL WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING. 1. Set parking brake. 2. Disconnect battery negative cable. A/C Service Ports 3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper Control Module/Service and Repair 5. Pinch off rear heater lines if equipped. Heater Hoses 6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7202 Expansion Valve Plate 7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair". See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 9. Remove heater ducts. 10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the tunnel. HVAC Bolt Up 11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12 Disconnect the HVAC housing wiring harness. 13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle. INSTALLATION 1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic and Cool-down test. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7203 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Housing Removal and Installation NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. 2. Hoist vehicle. A/C Lines 3. Remove A/C lines at lower floor pan flange. A/C Mounting 4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7204 Quarter Trim Panel 6. Remove right quarter trim panel and D-pillar trim. Lower Heater Duct 7. Remove screws securing air distribution duct to the rear wheel housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7205 Heater Core Lines 8. Pinch off heater lines at heater core hookup. Heater Hoses 9. Remove heater hoses at heater core. Trim Panel Mounting Bracket 10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness connector. Upper Duct Trim 12. Remove rear upper duct trim screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7206 Mounting Bolts 13. Remove (2) Heater-A/C housing mounting bolts. A/C Unit Replacement 14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan. Remove unit from the vehicle. INSTALLATION Filling Heater Core - For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7207 used: Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor ON HIGH, - Discharge air temperature, measured at the dual register located on the C-pillar base, is between 135 degree and 145 degree Fahrenheit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7208 Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE. 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C plumbing from rear heater A/C unit. 2. Hoist vehicle. A/C Lines 3. Remove A/C lines at lower floor pan flange. A/C Mounting 4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7209 Quarter Trim Panel 6. Remove right quarter trim panel and D-pillar trim. Lower Heater Duct 7. Remove screws securing air distribution duct to the rear wheel housing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7210 Heater Core Lines 8. Pinch off heater lines at heater core hookup. Heater Hoses 9. Remove heater hoses at heater core. Trim Panel Mounting Bracket 10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness connector. Upper Duct Trim 12. Remove rear upper duct trim screw. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7211 Mounting Bolts 13. Remove (2) Heater-A/C housing mounting bolts. A/C Unit Replacement 14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan. Remove unit from the vehicle. INSTALLATION Filling Heater Core - For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance. NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled completely, the following procedure can be Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Evaporator Housing Disassembly and Assembly > Page 7212 used: Vehicle at room temperature. - Engine is brought up to operating temperature. - Front unit is OFF, temperature slides are at full HEAT position. - Engine is at idle. - With rear blower motor ON HIGH, - Discharge air temperature, measured at the dual register located on the C-pillar base, is between 135 degree and 145 degree Fahrenheit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications Receiver Dryer: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 7216 Filter Drier Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications > Page 7217 Receiver Dryer: Service and Repair REMOVAL WARNING: The refrigeration system must be completely empty before proceeding with this operation. Filter Drier 1. Recover A/C system refrigerant. 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation, replace both refrigerant line 0-rings. Then reverse the above procedures. 2. Evacuate and recharge system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R134a Single Capacity ........................................................................................................................ ........................................ 0.96 kg (34 oz. or 2.13 lbs) R134a Dual Capacity ........................................................................................................................... ....................................... 1.36 kg (48 oz. or 3.00 lbs) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7222 Refrigerant: Fluid Type Specifications Hydrofluorocarbon (HFC), ................................................................................................................... ............................................... R-134a liquefied gas Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7223 Refrigerant: Description and Operation This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquefied gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge and/or poor performance. Never add any other type of refrigerant to a system designed to use R-134a refrigerant. System failure will occur. The high pressure service port is located on the liquid line near the strut tower. The low pressure service port is located on the suction line near the compressor manifold. Refrigerant Recovery/Recycling Station (Typical) When servicing a system, it is required that an air conditioning charging recovery/recycling machine be used. Contact an automotive service equipment supplier for proper equipment. Refer to the operating instructions provided with the equipment for proper operation. Manifold Gauge Set - Typical A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling device. Only use gauges that have not been used for R-12. The service hoses on the gauge set should have manual (turn wheel) or automatic back flow valves at the service port connector ends. This will prevent refrigerant R-134a from being released into the atmosphere. R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the oil that is specified on the under hood label. Due to the different characteristics of R-134a it requires all new service procedures. The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and low global warming impact. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications Refrigerant Filter: Specifications CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Front A/C - Compressor ....................................................................................................................................... ................................................... 150 ml (5.0 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) Dual A/C - Compressor ....................................................................................................................................... ................................................... 220 ml (7.4 oz) - Filter-Drier ......................................................................................................................................... .................................................... 30 ml (1.0 oz) - Condenser ......................................................................................................................................... ..................................................... 30 ml (1.0 oz) - Evaporator ......................................................................................................................................... .................................................... 60 ml (2.0 oz) - Rear Evaporator ................................................................................................................................ ..................................................... 60 ml (2.0 oz) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications > Page 7227 Refrigerant Filter: Service and Repair REMOVAL WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. 1. Recover A/C system refrigerant. Filter Drier Assembly 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location. INSTALLATION 1. Before installation, replace both refrigerant line O-rings. Then reverse the above procedure. Torque filter/drier mounting bolts to 45 in. lbs. +/- 10. 2. Evacuate and recharge system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Compressor ......................................................................................................................... ............................................................ 150 ml 5.0 oz. Dual A/C Compressor .......................................................................................................................... ............................................................ 220 ml 7.4 oz. Dual A/C Evaporator ............................................................................................................................ .............................................................. 60 ml 2.0 oz. Condenser ........................................................................................................................................... ................................................................ 30 ml 1.0 oz. Evaporator ........................................................................................................................................... ............................................................... 60 ml 2.0 oz. Filter-Drier ...................................................... ................................................................................................................................................... 30 ml 1.0 oz. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7232 Refrigerant Oil: Fluid Type Specifications Synthetic-based, Polyalkylene Glycol .................................................................................................. .......................................................................... ND-8 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7233 Refrigerant Oil: Service and Repair Refrigerant Oil Capacities Refrigerant Oil Level Check When all air conditioning system is first assembled, all components (except the compressor) are refrigerant oil free. After the system has been charged with R134a refrigerant and operated, the oil in the compressor is dispersed through the lines and components. The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained in the rest of the system must be drained from the replacement compressor. When a line or component has ruptured and oil has escaped, the compressor should be removed and drained. The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus the amount of oil still in the remaining components, can be measured and poured into the suction port of the compressor. Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz) of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz). CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG (polyalkalene glycol). Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add system capacity minus the capacity of components that have not been replaced through suction port on compressor. Refer to the Refrigerant Oil Capacity Chart. 6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions NUMBER: 26-03-98E GROUP: Miscellaneous DATE: March, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number 81-699-97028 DESCRIPTION OF CHANGES Revision to the Speed Control Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7238 76 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7239 78 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7240 80 Revision to the EGR System Failure Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7241 235 Revision to the A/C Pressure Sensor Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7242 292 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7243 296 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7244 A/C Pressure Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7245 A/C Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 7251 Blower Motor Relay: Locations Rear Blower Relay Rear Blower Motor Relay This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay Blower Motor Relay: Description and Operation Front Blower Motor Relay Circuit Operation Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1. The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power Distribution Center (PDC). The coil side of the relay is energized when the ignition switch is in the RUN position only. Power for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the relay Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit A22. Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl panel. Ground for the blower motor is controlled through the blower motor resistor and the blower motor switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay > Page 7254 Blower Motor Relay: Description and Operation Rear Blower Relay Circuit Operation Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear blower motor passes through the temperature sensor and one or more resistors, depending on speed selection. Two switches operate the rear blower motor by supplying ground; the front control switch and the rear control switch. The front control switch must be in the ON position for the rear control switch to operate the rear blower motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Component Locations > Page 7259 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch > Component Information > Description and Operation Air Conditioning Switch: Description and Operation SYSTEM OPERATION HVAC Mounted Switch HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Service and Repair Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw holding sensor to radiator closure panel. 3. Remove sensor from vehicle. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation SYSTEM OPERATION The rear blower speed switch controls the rear blower with the choice of low and high speeds. When the switch is on it allows the blower speed switch located on the rear headliner to control rear blower speed. This switch will override the rear headliner blower switch. For operation instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from the A/C control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection The evaporator probe can be tested by using the INTERMITTENT LED to display the actual temperature the sensor is reading. The HVAC control module can only display temperatures from 1 to 99 degrees. To read the temperature, perform the following: - Set Blower motor to any speed other than OFF - Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then, press and hold the intermittent wipe button for 5 seconds. - Run Diagnostics (Depress REAR WIPER and REAR WASH) - When Diagnostics is complete, Cycle to Level 4. - Display Sequence is as follows: - REAR WIPER LED will display the Level - INTERMITTENT LED will display ten's digit - Short Pause - INTERMITTENT LED will display the one's digit. The HVAC control module will continue to cycle the Level and then Temperature until the level is changed or Calibration Diagnostics and Cool-down test is exited. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Testing and Inspection > Page 7273 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the glove box. Evaporator Probe Connector 2. Disconnect the evaporator probe connector. Evaporator Probe Grommet 3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing. Evaporator Probe 4. Remove evaporator probe from evaporator. INSTALLATION - For installation, reverse the above procedures. Three holes are provided in evaporator for probe location. When reinstalling probe, use a different hole than original one. If a new evaporator is installed, insert the probe in the uppermost hole provided. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions NUMBER: 26-03-98E GROUP: Miscellaneous DATE: March, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number 81-699-97028 DESCRIPTION OF CHANGES Revision to the Speed Control Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7278 76 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7279 78 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7280 80 Revision to the EGR System Failure Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7281 235 Revision to the A/C Pressure Sensor Test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7282 292 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7283 296 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7284 A/C Pressure Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7285 A/C Pressure Sensor Connector Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation SYSTEM OPERATION Valve Service Ports The A/C service port valve cores are located within the A/C lines. The High Side (Discharge) valve service port is located on the liquid line near the right frame rail. The Low Side (Suction) valve service port is located on the suction line near the compressor. The High Side service port is a two piece port and is serviceable. The Low Side service port is not serviceable, the suction line would have to be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 7289 Service Port HVAC: Service and Repair WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION. The High Side service port is serviceable, the Low Side is not serviceable. REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Unscrew the High Side service port from the liquid line. 4. Remove O-ring INSTALLATION For installation, reverse the above procedures. Install new O-ring. - Evacuate and recharge A/C system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7297 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Airbag/Clock Spring - Service > Page 7302 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7303 Air Bag: Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7304 Air Bag: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Module Storage & Handling Air Bag: Service and Repair Airbag Module Storage & Handling DEPLOYED MODULE The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of airbag deployment. Sodium hydroxide powder can irritate the skin, eyes, nose and throat. Wear safety glasses, rubber gloves, and long sleeved clothing when cleaning any of the powder residue from the vehicle. If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. UNDEPLOYED The airbag modules must be stored in its original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag module. When carrying or handling an undeployed airbag module, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed airbag face down on a solid surface, the airbag will propel into the air if accidentally deployment occurs. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Module Storage & Handling > Page 7307 Air Bag: Service and Repair Driver Side Airbag Module Replacement WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIR-BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIR BAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. DEPLOYED MODULE The Driver Airbag Module and Driver Airbag Cover/Horn Pad are serviced separately from each other. REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. 2. Clean powder residue from interior of vehicle, refer to Cleanup Procedure. Airbag/Horn Switch 3. Remove three screws attaching Driver Airbag Module to steering wheel. 4. Remove airbag module from steering wheel. 5. Disconnect wire connectors from Airbag Module, horn switch, and speed control switches. 6. Adjust the steering wheel so that the tires are in a straight ahead position. Remove steering wheel. 7. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness. 8. Remove upper and lower steering column shrouds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Module Storage & Handling > Page 7308 Clockspring Locking Tabs 9. Remove clockspring from the housing assembly by depressing the 2 tabs on the clockspring. 10. Remove screws holding speed control switches to airbag cover and remove, if equipped. INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. UNDEPLOYED MODULE REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module (ACM) to discharge. 2. Remove screws attaching airbag/horn switch to steering wheel. 3. Remove Driver Airbag Module from steering wheel. 4. Disconnect wire connectors from airbag module, horn switch, and speed control switches, if equipped. 5. Remove screws holding vehicle speed control switches to airbag cover and remove. INSTALLATION For installation, reverse the above procedures and do not connect battery negative cable. Do not connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Module Storage & Handling > Page 7309 Air Bag: Service and Repair Passenger Side Airbag Module Replacement WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIR-BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. DEPLOYED MODULE REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module to discharge. 2. Clean powder residue from interior of vehicle, refer to Cleanup Procedure. 3. Remove instrument panel. 4. Remove all reusable components from the upper instrument panel. INSTALLATION Transfer all reusable components to the new the upper instrument panel. 1. Install new Passenger Airbag Module into instrument panel. 2. Install airbag module attaching screws to the instrument panel. 3. Install Instrument panel. 4. Through access holes in instrument panel above glove box opening, install screws holding airbag to back of panel. Airbag Upper Attachment 5. Install the bolts attaching forward airbag mount to the instrument panel. 6. Connect yellow wire connector from passenger airbag. 7. Install the glove box. 8. Install right front instrument panel speaker. 9. Install instrument panel top cover. 10. Do not connect battery negative cable. UNDEPLOYED REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. 2. Remove instrument panel top cover. 3. Remove right front instrument panel speaker. 4. Remove glove box. 5. Disconnect yellow wire connector from passenger airbag. 6. Remove bolts attaching forward airbag mount to the instrument panel 7. Through access holes in instrument panel above glove box opening, remove screws holding airbag to back of panel. 8. Remove screws attaching airbag to upper instrument panel. 9. Remove airbag from instrument panel through top of instrument panel. INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7313 Air Bag Control Module: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7314 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Airbag Module Locations Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag. The airbag cover/horn switch is serviced separately from the inflator and bag components. The Passenger Airbag Module is serviced as an assembly. WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY - LOWER STEERING COUPLER - STEERING WHEEL - STEERING COLUMN CLOCKSPRING - DRIVER AIRBAG COVER/HORN SWITCH - DRIVER AIRBAG MODULE - PASSENGER AIRBAG MODULE - UPPER INSTRUMENT PANEL WITH PAD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7315 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7316 Air Bag Control Module: Service and Repair WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module (ACM) to discharge. 2. Remove forward lower console from instrument panel. Heat Duct 3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from instrument panel. 5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7317 ACM Connectors 8. Disconnect two wire connectors from ACM. 9. Remove four bolts holding the ACM bracket assembly to floor. 10. Remove the ACM from vehicle. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7322 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7323 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7324 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7325 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7326 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7327 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7328 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7329 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7330 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7331 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7332 PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7333 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7334 POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: Recalls Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7347 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7348 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7349 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7350 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7351 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7352 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA02V293000 > Nov > 02 > Recall 02V293000: Clockspring Assembly Replacement Clockspring Assembly / Spiral Cable: Recalls Recall 02V293000: Clockspring Assembly Replacement DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during the vehicle assembly process. This condition will cause illumination of the air bag warning lamp, and could eventually cause the driver's air bag to become inoperative. REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less. An extended lifetime warranty will also be given for this component for all affected vehicles, regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The manufacturer has reported that owner notification began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement Technical Service Bulletin # B24 Date: 021101 Recall - Clockspring Inspection/Replacement November, 2002 Safety Recall No. B24 - Clockspring/Lifetime Warranty Effective immediately, all repairs on involved vehicles are to be performed according to this recall. Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year vehicles. Models: 1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The clockspring for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the table shown (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or > Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers): Note: Sales Code NHM is for Speed Control. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to service vehicles without speed control. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7361 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the clockspring assembly plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of the dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Function 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RDB24" Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair Vehicles Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7362 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches (if equipped) (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7363 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7364 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multifunction switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7365 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7366 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: Customer Interest Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7372 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7373 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7378 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7379 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7380 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7381 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7382 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7383 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7393 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7394 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7395 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7396 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7397 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7398 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA02V293000 > Nov > 02 > Recall 02V293000: Clockspring Assembly Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 02V293000: Clockspring Assembly Replacement DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during the vehicle assembly process. This condition will cause illumination of the air bag warning lamp, and could eventually cause the driver's air bag to become inoperative. REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less. An extended lifetime warranty will also be given for this component for all affected vehicles, regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The manufacturer has reported that owner notification began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement Technical Service Bulletin # B24 Date: 021101 Recall - Clockspring Inspection/Replacement November, 2002 Safety Recall No. B24 - Clockspring/Lifetime Warranty Effective immediately, all repairs on involved vehicles are to be performed according to this recall. Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year vehicles. Models: 1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The clockspring for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the table shown (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or > Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers): Note: Sales Code NHM is for Speed Control. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to service vehicles without speed control. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7407 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the clockspring assembly plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of the dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Function 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RDB24" Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair Vehicles Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7408 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches (if equipped) (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7409 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7410 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multifunction switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7411 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7412 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7417 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7418 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7423 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7428 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7429 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7430 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7431 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7432 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7433 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON Intermittently/Constantly NUMBER: 08-011-02 GROUP: Electrical DATE: Aug. 19, 2002 SUBJECT: Air Bag Warning Indicator Lamp On OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either intermittently or constantly. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The air bag warning indicator lamp may be on intermittently or constantly. DIAGNOSIS: If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body Diagnostic Manual leads to replace the clockspring because of high resistance, perform the following additional diagnostic procedure. DISCUSSION: When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing and replacing any component. When diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool 8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test components and wiring. Only replace and/or repair the component or wiring that has been identified with the 8310 Airbag Load Tool and the DRBIII(R). NOTE: AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310 AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT. NOTE: RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE CLOCKSPRING FOR THE DRIVER'S SQUIB. PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7439 EQUIPMENT POSSIBLY REQUIRED: REPAIR PROCEDURE: 1. Determine if the Driver Squib Circuit Open DTC is active or stored. a. If DTC is active proceed to step 2. b. If DTC is stored proceed to step 3. 2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring, verify the DTC remains by turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present at this time, proceed to step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position and verify that the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the 8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display. a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to lock, continue with step 3c. c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the connector. Reconnect the two-way (yellow) connector to the base of the clockspring. d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position, back to the full right lock position, and then back to the centered position. If the resistance value is now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is complete. Proceed to step 4. If not, proceed to next step. e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the clockspring, proceed to step 4. 4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7440 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service NUMBER: 08-010-01 GROUP: Electrical DATE: May 25, 2001 SUBJECT: Airbag/Clock Spring Service MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2002 (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1988 - 1993 (AG) Daytona 1988 - 1995 (AJ) Lebaron Coupe/Convertible 1990 (AL) Horizon/Omni 1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1994 - 2002 (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2002 (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - 2002 (DN) Durango 2002 (DR) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 (KJ) Liberty 1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2002 (PL) Neon 1997 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2002 (PT) PT Cruiser 2001 - 2002 (RG) Chrysler Voyager (International Markets) 2001 - 2002 (RS) Town & Country/Caravan/Voyager 1996 - 2002 (SR) Viper 2001 - 2002 (ST) Sebring Coupe/Stratus Coupe 1997 - 2002 (TJ) Wrangler 2001 - 2002 (WG) Grand Cherokee (International Markets) 1999 - 2002 (WJ) Grand Cherokee 1995 - 2001 (XJ) Cherokee 1995 - 1998 (ZG) Grand Cherokee (International Markets) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Airbag When servicing any airbag system, it is essential to follow the proper Service Manual and/or Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only replace the component or wiring that has failed. This will reduce unnecessary cost to the customer or DaimlerChrysler. NOTE: AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED. NOTE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7445 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7450 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7451 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7452 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7453 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7454 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7455 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag Clockspring Replacement Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan 1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth / Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V480000 Recall Date : OCT 05, 2004 COMPONENT: Air Bags Potential Number Of Units Affected : 955344 SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the clockspring, which is located in the hub of the steering wheel. CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a reasonable amount of time. REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an extended lifetime warranty under which it will replace the clockspring at no charge if it fails. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension Technical Service Bulletin # D17 Date: 041001 Recall - Clockspring Replacement/Warranty Extension October 2004 Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty Models 1998-2000 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP function. Note: Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with speed control and radio controls. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7465 submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle list All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, VIP and Dealer Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7466 Customer Services Field Operations Daimler Chrysler Corporation Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. IMPORTANT: If an owner requests this recall service on a minivan that has more than 70,000 miles and an AIRBAG light that operates normally even though the owner letter clearly states that no action is necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3 of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present. 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7467 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7468 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multi-function switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches and steering wheel mounted radio controls (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7469 between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7470 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > NHTSA02V293000 > Nov > 02 > Recall 02V293000: Clockspring Assembly Replacement Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 02V293000: Clockspring Assembly Replacement DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during the vehicle assembly process. This condition will cause illumination of the air bag warning lamp, and could eventually cause the driver's air bag to become inoperative. REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less. An extended lifetime warranty will also be given for this component for all affected vehicles, regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on their vehicles. The manufacturer has reported that owner notification began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement Technical Service Bulletin # B24 Date: 021101 Recall - Clockspring Inspection/Replacement November, 2002 Safety Recall No. B24 - Clockspring/Lifetime Warranty Effective immediately, all repairs on involved vehicles are to be performed according to this recall. Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year vehicles. Models: 1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX). IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System. Subject: The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash. Repair Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring assembly replaced. Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring assembly. NOTE: This recall does NOT include replacement of other airbag system components. If other components cause illumination of the airbag warning light, the associated repair costs are the owner's responsibility. Parts Information Dealers should determine which clockspring is required for each vehicle at the time appointments are scheduled to assure that the correct part is available when the customer arrives. The clockspring for the vehicle to be serviced may be determined by: > Using the part code in the third column of the VIN list along with the table shown (involved dealers); > Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or > Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers): Note: Sales Code NHM is for Speed Control. Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to service vehicles without speed control. Additional clockspring assemblies may be ordered as necessary. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7479 service completions and provide dealer payments. Use one of the labor operation numbers and time allowances shown. Add the cost of the clockspring assembly plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Parts Return Not required. Dealer Notification and Vehicle List All dealers will receive a copy of the dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. Dial System Function 53 and VIP All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RDB24" Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair Vehicles Not Available If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to: DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757 Additional Information If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Service Procedure 1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if it is functioning properly. Proceed to Step 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7480 2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the ON position. 3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC). > If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring assembly MUST be replaced. Erase the DTC and continue with Step 4. > If there are no DTC's or if any other airbag system DTC is present, the recall service procedure does not apply. Diagnosis and repairs are the owner's responsibility. 4. Place the front wheels in the straight-ahead position. 5. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). 7. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire connector on the back of the airbag module (Figure 2). 9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag module by firmly grasping and pulling, or gently prying, the connector. NOTE: Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module connector receptacle. 10. Disconnect the clockspring wire harness connectors from the speed control switches (if equipped) (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7481 11. Remove the airbag module and set it aside. 12. Remove the steering wheel nut. 13. Remove the steering wheel damper from the steering wheel (if equipped). 14. Remove the steering wheel from the steering column using a steering wheel puller (Special Tool C-3428-B). 15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column, then remove the shrouds from the steering column (Figure 3). 16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7482 17. Remove the clockspring from the multi-function switch by depressing the two tabs on the clockspring (Figure 5). Discard the clockspring assembly. 18. Slide the new clockspring over the steering column shaft until the clockspring latches engage the multifunction switch housing (Figure 5). 19. Connect the wire harness connectors to the clockspring assembly (Figure 4). 20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws securely. 21. Install the steering wheel onto the steering column shaft. 22. Install the steering wheel damper (if equipped). 23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m). 24. Connect the clockspring wire harness connectors to the speed control switches (if equipped) (Figure 2). 25. Connect the clockspring airbag wire harness connector to the back of the airbag module (Figure 2). 26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector on the back of the airbag module (Figure 2). 27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel. 28. From the backside of the steering wheel, install the three (3) screws that secure the driver's airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m). 29. With the ignition switch in the ON position, connect the negative battery cable. 30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and then turn it back to the ON position. 31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds and then go out. NOTE: If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to the proper Body Diagnostic Procedures manual to diagnose and repair the problem. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7483 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7484 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7489 TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT CODES ON THE REPAIR ORDER. Clock Springs Recent analysis of returned clock springs have indicated that prior service may have contributed to the clock spring's failure. ^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often used in the clock spring area of the steering column to eliminate noise. Lubricants may have an adverse effect on the clock spring. ^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the front wheels will require that the clock spring be centered. This includes clock spring replacement, steering column service, HVAC service, steering gear service, and front suspension crossmember service. Refer to the appropriate Service Manual for the clock spring centering procedure. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Component Locations > Page 7492 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7493 Clockspring Assembly / Spiral Cable: Description and Operation SYSTEM OPERATION The clockspring is snapped into a plastic mounting platform on the steering column behind the steering wheel. The clockspring is used to maintain a continuous electrical circuit between the wiring harness and the driver's airbag module. This assembly consists of a flat ribbon like electrically conductive tape which winds and unwinds with the steering wheel rotation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7494 Clockspring Assembly / Spiral Cable: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7495 Clockspring Assembly / Spiral Cable: Adjustments CLOCKSPRING CENTERING PROCEDURE If the rotating tape (wire coil) in the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail. The following procedure MUST BE USED to center the clockspring if it is not known to be properly positioned, or if the front wheels were moved from the straight ahead position. WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. 1. Adjust the steering wheel so that the tires are in a straight ahead position. 2. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. 3. Remove Driver Airbag Module from steering wheel. 4. Disconnect wire connectors from back of airbag module. 5. Remove steering wheel. Clockspring Locking Tabs 6. Depress the two plastic locking pins to disengage lock mechanism. 7. With lock mechanism disengaged, rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive force. 8. From the end of travel, rotate the rotor three turns counterclockwise. The wires should end up at the top. Release locking pins to engage clockspring lock mechanism. 9. Install steering wheel and airbag. 10. Do not connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7496 Clockspring Assembly / Spiral Cable: Service and Repair WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING AIR- BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and open hood. 3. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to discharge. Airbag/Horn Switch 4. Remove driver airbag from steering wheel. 5. Disconnect wire connectors from back of airbag module. 6. Remove steering wheel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7497 7. Remove steering column shrouds. 8. Disconnect 2-way and 4-way connectors between the clockspring and the instrument panel wiring harness. Clockspring Locking Tabs 9. Remove clockspring from housing assembly by depressing the two tabs on the clockspring. INSTALLATION For installation, reverse the above procedures. Do not connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing and Inspection Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Testing and Inspection Malfunction Lamp / Indicator: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7508 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7509 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7510 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7511 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 7512 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7517 Air Bag Control Module: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7518 Air Bag Control Module: Description and Operation SYSTEM OPERATION The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The ACM monitors the system to determine the system readiness. The ACM contains on-board diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs. The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or serious injury, caused by a frontal impact of the vehicle. The impact sensor provides verification of the direction and severity of the impact. One impact sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a bracket, just forward of the center console. The impact sensor is an accelerometer that senses deceleration. The deceleration pulses are sent to a microprocessor which contains a decision algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor is calibrated for the specific vehicle and reacts to the severity and direction of the impact. Airbag Module Locations Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag. The airbag cover/horn switch is serviced separately from the inflator and bag components. The Passenger Airbag Module is serviced as an assembly. WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY - LOWER STEERING COUPLER - STEERING WHEEL - STEERING COLUMN CLOCKSPRING - DRIVER AIRBAG COVER/HORN SWITCH - DRIVER AIRBAG MODULE - PASSENGER AIRBAG MODULE - UPPER INSTRUMENT PANEL WITH PAD. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7519 Air Bag Control Module: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7520 Air Bag Control Module: Service and Repair WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS. REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the Airbag Control Module (ACM) to discharge. 2. Remove forward lower console from instrument panel. Heat Duct 3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from instrument panel. 5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7521 ACM Connectors 8. Disconnect two wire connectors from ACM. 9. Remove four bolts holding the ACM bracket assembly to floor. 10. Remove the ACM from vehicle. INSTALLATION WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED. CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7528 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether Installation NUMBER: 23-029-08 GROUP: Body DATE: October 24, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR MILEAGE. SUBJECT: Child Seat Tether Anchor Installation OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on Customer Request. NOTE: Dealers are encouraged to honor any customers request for the installation of the Child Seat Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for reimbursement detail. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shawdow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7534 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 2000 (TJ) Wrangler 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. NOTE: This bulletin is provided to identify the parts and labor operation numbers necessary to install a Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits regardless of vehicle age or mileage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7535 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7536 PARTS REQUIRED: POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7537 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7538 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7539 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7540 Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts Identification NUMBER: 23-35-99 Rev. A GROUP: Body DATE: Oct. 1, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME ALLOWANCES. SUBJECT: Child Seat Tether Anchors NOTE: THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) LeBaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2000 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS 1999 - 2000 (WJ) Grand Cherokee 1989 - 2000 (XJ) Cherokee/Wagoneer 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7541 detailed instruction sheet. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7542 PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7543 POLICY: Customer Satisfaction Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7544 TIME ALLOWANCE: Failure Code: CG - Customer Satisfaction Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7545 Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7546 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7547 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7548 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7549 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7550 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become Inoperative Seat Belt: Recalls Recall 02V076000: Seat Belt May Become Inoperative Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of personal injury. Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat belt assemblies. The manufacturer has reported that owner notification is expected to begin during June 2002. Owners who do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become Inoperative Seat Belt: All Technical Service Bulletins Recall 02V076000: Seat Belt May Become Inoperative Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of personal injury. Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat belt assemblies. The manufacturer has reported that owner notification is expected to begin during June 2002. Owners who do not receive the free remedy within a reasonable time should contact DaimlerChrysler at 1-800-853-1403. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7569 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7570 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7571 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7572 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7573 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7574 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7575 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7576 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7577 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7578 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7579 PARTS REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7580 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7581 POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Testing and Inspection Impact Sensor: Testing and Inspection Chrysler does not provide a procedure to retrieve trouble codes without a scan tool. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation Antenna: Description and Operation SYSTEM OPERATION All models use a fixed-length stainless steel rod-type antenna mast, installed at the right front fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna cable, and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis. The antenna coaxial cable has an additional disconnect, located near the right end of the instrument panel. This additional disconnect allows the instrument panel assembly to be removed and installed without removing the radio. The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and Operation > Page 7589 Antenna: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. The following four tests are used to diagnose the antenna with an ohmmeter: - Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground to battery ground test - Test 4 - Body ground to coaxial shield test. Antenna Tests The ohmmeter test lead connections for each test are shown in Antenna Tests . NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem; from the coaxial cable connection under the right end of the instrument panel near the right cowl side panel to the antenna base, and then from the coaxial cable connection to the radio chassis connection. Test 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis and isolate. 2. Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base. Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or damaged antenna base and cable assembly. Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial cable connector from the radio chassis. 2. Connect one ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the center pin of the antenna coaxial cable connector. 3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace the faulty base and cable, if required. Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the battery Disconnect both battery cables, the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery negative post. 2. The resistance should be less than (1) ohm. 3. If the resistance is more than (1) ohm, check the braided ground strap connected to the engine and the vehicle body for being loose, corroded, or damaged. Repair the ground strap connection, if required. Test 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then (1) ohm. 3. If the resistance is more then (1) ohm, clean and/or tighten the antenna base to fender mounting hardware. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable Antenna: Service and Repair Antenna Extension Cable REMOVAL 1. Remove glove box. Antenna Cable 2. Disconnect extension cable end from antenna cable end. 3. Disconnect cable hanger clip from HVAC unit. 4. Remove radio as necessary to gain access to extension cable. 5. Disconnect extension cable from back of radio. 6. Remove extension cable from vehicle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable > Page 7592 Antenna: Service and Repair Antenna Mast and Cable Lead REMOVAL 1. Remove glove box from instrument panel. Antenna Cable 2. Disconnect antenna cable connector from extension cable. 3. Remove right kick trim panel. 4. Disengage rubber grommet insulator from door hinge pillar. 5. Pull antenna cable through hinge pillar into open between door hinges. 6. Hoist and support vehicle on safety stands. 7. Remove front wheel. 8. Remove front wheelhouse splash shield. Antenna Mast 9. Slide the plastic sleeve up on antenna mast for access to mast. Remove antenna mast from antenna base. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and Repair > Antenna Extension Cable > Page 7593 Antenna Cap Nut Remove/Install - Typical 10. Remove plastic cap from the cap nut. Using cap nut tool, remove cap nut holding antenna base to front fender. 11. Remove antenna base from under front fender. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL 1. Open the front door. Front Door Ajar Switch 2. Remove the screw holding the door ajar switch to the door B-pillar. 3 Remove the door ajar switch from the B-pillar. 4. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION - For installation, reverse the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 7599 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL 1. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar switch. 4. Remove the sliding door ajar switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7607 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7608 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7609 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Page 7624 Keyless Entry Transmitter Battery: Application and ID The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch REMOVAL 1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4. Remove the outer handle from the door. Door Lock Cylinder Switch 5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch from the door handle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch > Page 7629 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL 1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 7634 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7639 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7640 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7641 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations Technical Service Bulletin # 08-23-99 Date: 990709 Radio Communication Equipment - Recommendations NUMBER: 08-23-99 GROUP: Electrical DATE: Jul. 9, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000 MODEL YEAR VEHICLES. SUBJECT: Installation of Radio Transmitting Equipment MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000** (DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ) Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in properly installing communication equipment in DaimlerChrysler vehicles. This information should be given to any owner inquiring about installing radio-transmitting equipment. Installation Recommendations DaimlerChrysler Radio Communication Equipment Installation Recommendations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7646 The following is excerpted from the owners manual of new DaimlerChrysler products: "INSTALLATION OF RADIO TRANSMITTING EQUIPMENT Special design considerations are incorporated into this vehicle's electronic system to provide immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be installed properly by trained personnel. The following must be observed during installation. The positive power connection should be made directly to the battery and fused as close to the battery as possible. The negative power connection should be made to body sheet metal adjacent to the negative battery connection. This connection should not be fused. Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or operation of the compass on vehicles so equipped. The antenna cable should be as short as practical and routed away from the vehicle wiring when possible. Use only fully shielded coaxial cable. Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR). Mobile radio equipment with output power greater than normal may require special precautions. All installations should be checked for possible interference between the communications equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for detailed assistance." The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good construction practices (see The ARRL Handbook or other standard reference works). The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. The responsibility for installations and modifications is the sole responsibility of the customer. The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. 1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan, put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind instrument panel. If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed. Try the installation out before you start drilling holes. 2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.: radio presets) after a protracted time without battery power. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7647 For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +) lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with cover 12033731 for standard SAE plastic fuses. Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas. Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest location. DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which could cause the feedline to overheat, with possible resulting damage. For low or medium power installations, connect the ground (battery -) to body sheet near the power feed point. If you use a screw through the floor, put body sealer over the underbody projection. (Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high power installations, connect the ground (battery -) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected (usually the case with commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the terminal and the screw head. As above, some grease or protectant should be used if the connection is in an unprotected area. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Tie wrap as required. 3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness (usually on the left side). Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible. 4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable. Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle. In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not pile things on top of the unit. 5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military "RG" designations as an indicator of quality. Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the correct connector. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information > Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7648 The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses. 6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass antennas may be damaged by through-glass installations. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection. 7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from the feedline inside the passenger compartment, and may be picked up by the vehicle wiring. For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short, wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood must be bonded to the body. In some cases the doors may need to be bonded, as well. Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius approximately equal to the length of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof mechanism for interference to the base and to the feedline. For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base. To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through, leaving 6 in., which can be taped, to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process. In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar. Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important. Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7653 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7654 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7668 Driver/Vehicle Information Display: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Driver/Vehicle Information Display: Electrical Diagrams Information Center Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 Message Center (Part 1 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Message Center (Part 2 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Message Center (Part 3 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Message Center (Part 4 Of 4) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Driver/Vehicle Information Display: Service and Repair Message Center REMOVAL 1. Remove A-pillar trim. 2. Remove instrument panel top cover. Refer to instrument panel top cover removal procedures. 3. Disconnect the wire connector from back of message center. 4. Remove screws holding message center to instrument panel top cover. 5. Remove message center from instrument panel top cover. INSTALLATION 1. Place message center in position on top cover. 2. Install screws to hold message center to instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install instrument panel top cover. 5. Install A-pillar trim. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center > Page 7679 Driver/Vehicle Information Display: Service and Repair Message Center Lamp REMOVAL 1. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Removal procedures. Message Center Lamp Location 2. Locate the lamp in question. 3. Remove lamp and check lamp. If lamp is good test the power supply to the lamp. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation Seat Memory Switch: Description and Operation SYSTEM OPERATION Memory Selector Switches The memory selector switches are mounted on the driver's door trim panel within easy reach of the driver. They provide a means to set or recall either of two positions of seat and recliner, and the side view mirrors as chosen by the driver. The inputs from these switches to the memory seat/mirror module is a ground level signal. 1. Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press any switches for 10 seconds. 4. To program the second driver's position, follow the above sequence. 5. To recall either of the programmed positions momentarily press and release either memory selector switch 1 or 2. Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 7684 Seat Memory Switch: Testing and Inspection To test the memory selector switch: 1. Remove the memory selector switch. Refer to removal procedure. Memory Selector Switch Continuity 2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 7685 Seat Memory Switch: Service and Repair REMOVAL 1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel. 2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Service and Repair Compact Disc Player (CD): Service and Repair REMOVAL 1. Remove HVAC switch bezel. Radio 2. Remove screws holding radio to instrument panel. Radio Connectors 3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from back of radio. 7. Remove radio from vehicle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Radio/Stereo Noise Filter: Customer Interest Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7699 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7700 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7701 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7702 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise Radio/Stereo Noise Filter: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise NUMBER: 08-45-99 GROUP: Electrical DATE: Dec. 31, 1999 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2, 1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. SUBJECT: AM Radio Reception OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module, adding a jumper harness, ground strap and tie-strap. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE. SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition noise (static that varies with engine RPM) on low power/distant stations. DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that varies with engine RPM is heard check the antenna connection, the antenna ground, the ground straps across the right side motor mount, and from the back of the engine to the dash panel. If these check ok but the static condition still exists, perform the Repair Procedure. PARTS REQUIRED: 1 05016107AA Shield Package Contents Of Shield Package: 1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts 1 05016105AA Wiring Repair Package 1996-1998 1 05016106AA Wiring Repair Package 1999-2000 Contents of Wiring Packages: 1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor, 1-Capacitor Mounting Bolt REPAIR PROCEDURE: 1. Disconnect the negative battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7708 Fig. 1 2. Disconnect the electrical connector from the ignition coil module, Figure 1. 3. Remove the ignition coil module bottom-forward mounting bolt and discard. Fig. 2 4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque the screw to 10-15 Nm (85-125 in. lbs.) 5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then connect the jumper harness between the ignition coil module and the powertrain harness connector, Figure 2. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7709 Fig. 3 Fig. 3A 6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of the powertrain harness (see fig. 3 or fig. 3a). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7710 Fig. 4 7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4. 8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs. Torque studs to 10-15 Nm (85-125 in. lbs.) Fig. 5 9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure 5. Torque the nuts to 10-15 Nm (85-125 in. lbs.). 10. Turn the ignition switch to the Unlock position so the steering wheel can rotate. 11. Raise vehicle. Then turn the front wheels to the left. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7711 Fig. 6 12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse panel/frame to 11 Nm (95 in. lbs.), Figure 6. 13. Center the front wheels and lower the vehicle. 14. Connect the negative battery cable and set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-12-02-91 0.4 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 7712 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7716 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches Remote Radio Switches Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right (Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7717 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. - Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 7721 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 7722 Speaker: Description and Operation SYSTEM OPERATION Name Brand Speaker Relay Relay is located in the junction block. To test relay refer to the Audio Diagnostic Test Procedures or use a known good relay. Choke Location Choke-Infinity Speakers If the audio system is lacking bass response, check for continuity across the choke connector. If no continuity Replace choke. The choke is located on the bracket behind the junction block/body control module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker Speaker: Service and Repair D-Pillar Speaker REMOVAL 1. Remove D-pillar trim panel as necessary to gain access to door speaker. 2. Disconnect wire connector from speaker. D-Pillar Speaker 3. Remove by sliding speaker out of bracket by pushing on magnet. The capacitor is wrapped with foam tape. 4. Remove speaker. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 7725 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Remove front door trim panel as necessary to gain access to door speaker. Front Door Speaker 2. Remove screws holding speaker to bracket. 3. Remove speaker from bracket. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 7726 Speaker: Service and Repair Instrument Panel Speaker REMOVAL 1. Remove instrument panel top cover. Left Instrument Panel Speaker Right Instrument Panel Speaker 2. Remove screws holding speaker to instrument panel and remove speaker. 3. Remove anti rocking finger screw. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 7727 Speaker: Service and Repair Quarter Panel Speaker REMOVAL 1. Remove quarter trim bolster from quarter trim panel. Quarter Panel Speaker 2. Remove screws holding speaker to inner quarter panel. 3. Separate speaker from quarter panel. 4. Disconnect wire connector from speaker. 5. Remove speaker. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair REMOVAL 1. Remove HVAC switch bezel. Radio 2. Remove screws holding radio to instrument panel. Radio Connectors 3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from back of radio. 7. Remove radio from vehicle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7735 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7736 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7737 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch REMOVAL 1. Open the front door. Front Door Ajar Switch 2. Remove the screw holding the door ajar switch to the door B-pillar. 3 Remove the door ajar switch from the B-pillar. 4. Disconnect the wire connector from the back of the ajar switch and remove the switch. INSTALLATION - For installation, reverse the above procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 7743 Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch REMOVAL 1. Release the sliding door latch and allow back of the door to pop open. Sliding Door Ajar Switch 2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar switch. 4. Remove the sliding door ajar switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch REMOVAL 1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4. Remove the outer handle from the door. Door Lock Cylinder Switch 5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch from the door handle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch > Page 7751 Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation Remote Switch: Description and Operation SYSTEM OPERATION Remote Radio Switch Operational View A remote radio control switch option is available on LXI models sold in North America with the AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended. For more information on the operation of the remote radio switch controls, refer to the owner's manual in the vehicle glove box. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7755 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switches Remote Radio Switches Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right (Left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK, repair the open circuit as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7756 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the airbag module away from the steering wheel far enough to access the wire harness connectors on the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module. 5. Remove the driver side airbag module from the vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side of switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers seat. INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be careful to index them correctly before pressing them into place. - Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch REMOVAL 1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar switch. Liftgate Ajar Switch 3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page 7761 Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch REMOVAL 1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside latch release handle. Liftgate Cylinder Lock Switch 4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 Trailer Connector: Electrical Diagrams Trailer Tow (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Trailer Tow (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 Trailer Connector: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 Trailer Connector: Electrical Diagrams Trailer Tow (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 Trailer Tow (Part 2 Of 2) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description and Operation Trip Computer: Description and Operation SYSTEM OPERATION Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC consists of an electronic module that displays compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC to change mode of operation when the ignition is ON. Examples: Compass/Temperature - Trip odometer (ODO) - Average miles per gallon (ECO) - Instant miles per gallon (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Off The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Testing Trip Computer: Testing and Inspection Testing The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool and the proper Body Control Module Testing and Inspection Procedures or by using the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check the CMTC will display. PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed replace the module. If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper operation. If the CCD bus and the BCM are OK, replace the CMTC module. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and Inspection > Testing > Page 7816 Trip Computer: Testing and Inspection Traveler Messages Traveler data is obtained from the Body Control Module (BCM) on the CCD bus wires. The CMTC will not display information for any of the screens for which it did not receive the bus messages. The label corresponding to the missing information will be lit. If no traveler data is displayed, check the CCD communications and the BCM. If the brightness level is improper check the CCD bus. One general method for checking the CCD bus communications between CMTC and the BCM is refer to the following procedure. 1. STEP the CMTC to the Elapsed Time (ET). 2. Press and release the reset button to reset the module. 3. If the elapsed time clock does not reset, or fails to update, check the CCD wires and the BCM. - A scan tool is recommended for checking the CCD and the BCM. 4. Perform the CMTC self diagnosis before replacing the module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Compass Mini-Trip Computer (CMTC) Module Trip Computer: Service and Repair Compass Mini-Trip Computer (CMTC) Module REMOVAL 1. Disconnect battery negative cable. 2. Remove overhead console. Compass Mini-Trip Computer 3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module from console. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and Repair > Compass Mini-Trip Computer (CMTC) Module > Page 7819 Trip Computer: Service and Repair Compass Mini-Trip Computer (CMTC) Lamp REMOVAL 1. Remove overhead console. CMTC Lamp Bulbs 2. Rotate bulb socket counterclockwise one quarter turn. 3. Pull bulb socket from CMTC module. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM - Auto Lamp DTC Diagnostics Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics NO: 08-40-98 GROUP: Electrical DATE: Sept. 25, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL VEHICLES. MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager DISCUSSION: During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head lamps. If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at erasing this erroneous DTC will be unsuccessful. If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan, Voyager and Town & Country Body Diagnostic Procedures Manual.** POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Body Control Module: Component Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 7828 Body Control Module Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7834 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7844 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7845 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7846 Body Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7847 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Body Control Module: Connector Views Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Body Control Module: Electrical Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Exterior Lighting (Park Lamps) Information Center Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 Instrument Cluster Interior Lighting Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 Power Door Locks W/Remote Keyless Entry (RKE) Power Door Locks W/O Remote Keyless Entry (RKE) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 Radio (CCD) Without Infinity Sound Radio (CCD) With Infinity Sound Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Vehicle Communications Vehicle Theft Security System (VTSS) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Windshield Wiper (Front) Windshield Wiper (Rear) Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 Body Control Module (Part 1 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 Body Control Module (Part 2 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Body Control Module (Part 3 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 Body Control Module (Part 4 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Body Control Module (Part 5 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Body Control Module (Part 6 Of 7) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Body Control Module (Part 7 Of 7) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following approved procedures is very important to the safety of individuals performing diagnostic tests. DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. Following these procedures is very important to the safety of individuals performing diagnostic tests Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 7869 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with rubbing alcohol. Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Servicing Sub-Assemblies Some components of the body system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced. DRBIII Safety Information WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: FUNCTION/INPUT LIMIT Volts 0 - 500 peak volts AC 0 - 500 volts DC Ohms (resistance)* 0-1.12 megohms Frequency Measured 0 - 10 kHz Frequency Generated 0 - 10 kHz Temperature -58 - 11000 F -50 - 600 C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ The circuit being tested must be protected by a 1OA fuse or circuit breaker. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Application and ID > Body Code Body Control Module: Application and ID Body Code Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager Body Code = NS Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Application and ID > Body Code > Page 7872 Body Control Module: Application and ID Glossary of Terms ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum Fluorescent Display VTSS Vehicle Theft Security System NOTE: The following terms are used interchangeably: - Left Front (LF) Door & Driver (DR) Door - Right Front (RF) Door and Passenger (PASS) Door - "Gage" and "Gauge" Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7875 Body Control Module: Description and Operation Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7876 Body Control Module: Description and Operation Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7877 Body Control Module: Description and Operation Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7878 Body Control Module: Description and Operation Airbag System SYSTEM DESCRIPTION The airbag system is designed to provide increased driver and passenger protection if the vehicle is involved in a front end collision. The system is most effective when used in conjunction with the seat belt system. Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of compressed, inert gas to inflate the bag, instead of sodium azide. Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a mechanically-triggered system utilizing two front impact sensors and a sensor inside the module. The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its own internal electronic sensor to trigger the airbags. These procedures will address the AECM type of module, the term "airbag control module" (or ACM) will be used to refer to the module. FUNCTIONAL OPERATION Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM) performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8 seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. The airbag system is monitored by the ACM. The ACM monitors critical input and output circuits within the airbag system, making sure they are operating correctly. Some circuits are tested continuously; others are checked only under certain circumstances. The ACM provides diagnostic information about the airbag system to the technician through the DRB via the CCD bus. The deceleration or g-force resulting from the impact of a front-end collision causes the electronic sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying the airbags. The total time between determining to deploy and full inflation of the airbag is approximately 40ms. A new enhanced accident response feature has been added. This feature, upon deployment of the airbag, turns on the interior lights and unlocks the power door locks (if equipped). The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be observed by the customer. Use the test procedures to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not come on at all warning lamp stays on Interior Lighting This feature provides a battery protection scheme to avoid wearing down the battery due to leaving a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM) provides a ground circuit for these interior lamps. This ground path is connected whenever the ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15 minutes timeout has expired, any monitored input that brings the BCM out of sleep mode (ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.) will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed). Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection from turning off these interior lamps as described above. Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off these interior lamps as described above. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions, To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD bus]). This network consists of the powertrain control module (PCM), the transmission control module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM), the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is operational when battery power is supplied to the module. Ignition switch power is needed for ignition switch functions. The body control module provides the following features: - automatic door locks - battery protection - chimes - compass/mini-trip support - courtesy lamps Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7879 - BCM diagnostic support - door lock inhibit - headlamp time delay - ignition key lamp - illuminated entry - instrument panel dimming - mechanical instrument cluster support - power door locks (with/without remote keyless entry) - sliding door memory lock - vehicle theft security system (VTSS) - windshield wipers / washers (front and rear) Chime System The chime system provides the driver with two types of chimes: warning and announcement. Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on, key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The warning chime will sound continuously until the condition is removed or the battery protection stops the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six seconds or until the seat belt is fastened. The announcement chime will act as a warning to the driver to scan the instrument cluster to observe which lamp is illuminated. The announcement chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered under the instrument cluster warning lamp diagnostics. Compass Mini-Trip Computer (CMTC) The compass/mini-trip computer is located in the overhead console. It displays to the driver the direction the vehicle is traveling and the current outside temperature, as well as the following traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE), instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information needed for the traveler functions is received over the CCD bus from the body control module. If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration. Auto Headlamps On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control the exterior lamp operation by monitoring the mode selection switch located in the headlamp control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see Headlamp Delay Feature description). Battery Protection: "Park & Headlamps" This feature provides a battery protection scheme to avoid wearing down the battery if the customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless Entry (RKE) actuation, etc.). Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory power on) will inhibit the battery protection routine from turning off the exterior lamps as described above. Exterior Headlamp Control The headlamps and parklamps are illuminated via external relays which are controlled by the body controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays. The position of the hi-beam select switch will determine the mode of operation. Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time. Headlamp Time Delay The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and passengers security lighting when exiting the vehicle. This feature is only available on vehicles equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp delay. This 45 second window is new for the NS body. Once the headlamp delay has been activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto headlamp or the ignition switch changes states. Identification of System Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7880 The vehicle systems that are part of the "body" system are: - airbag system - chimes - compass/mini-trip - courtesy lamps I panel dimming - headlamp time delay - illuminated entry - radio (CCD) - information center - mechanical instrument cluster (MIC) - power door locks - remote keyless entry (RKE) - vehicle communications - vehicle theft security system (VTSS) - wipers Vehicles equipped with the highline body control module can be identified by the presence of the vehicle theft security system (VTSS). Vehicles with the midline body control module may have a compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or illuminated entry. Vehicles with a base body control module will not have any of these features. Introduction Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover all the necessary requirements to begin a logical diagnostic path for each repair. If there is a trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are used to direct you alphabetically to the specific systems. NOTE: The following terms are used interchangeably: Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door Mechanical Instrument Cluster (MIC) The body control module sends the angular position of the gauges, the status of all CCD indicator lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped) and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions; all other MIC features work only when the ignition is in the "run" position. On transition of the ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine exceeds 450 rpm. Power Door Lock System When the body control module (BCM) receives an input for a lock request (door lock switch, RKE, or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck, the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates in the same fashion as the lock signal. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. Other power door lock features: Sliding Door Memory Lock When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on the lock relay as described above, and will turn it on again when all sliding doors are closed. NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the memory lock. Door Lock Inhibit When the key is in the ignition and in the off position, and any door except the rear liftgate is open, all door lock switches are disabled. The unlock switches are still functional. This protects against locking the vehicle with the keys still in the ignition. Automatic Door Locks This feature can be enabled or disabled by using either the DRBIII or customer programming method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will operate again once all doors are closed and the speed is above 15 MPH. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7881 RKE (Remote Keyless Entry) Interface The body control module interfaces with the RKE receiver via a one-way serial bus interface. The RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4 individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the BCM will ground the interface wire thereby disabling the RKE. The RKE module can be programmed via the DRBIII or customer programming method. The BCM will only allow programming mode to be entered when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is in the disarmed mode. Radio System There are three radio systems available this year that will be on the CCD bus. They are the RBR, RBN and RAZ models. The main reason they are on the bus is because of the radio remote controls in the steering wheel. They can control volume up/down, seek up, seek down and preset station selections. These systems also communicate with the body control module and will set a specific code if there is a problem with the remote controls. The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers receive their signals from the quarter speakers. Depending on the manufacture some systems will have a Front/Rear channel system and others will have a Left/Right channel system. If one of the main quarter speaker audio circuits experiences a short, the other speakers on that channel will also shut down until the circuit is repaired. The radio will also set a trouble code, which is assessible with the DRB, indicating which channel is effected. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) This passive system is designed to protect against theft. The vehicle theft security system (VTSS) is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature. Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's door, locking the doors with the power lock, and closing the driver's door or locking the doors with Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after closing them. The indicator lamp in the information center will flash for 15 seconds, showing that arming is in progress. If no monitored systems are activated during this period, the system will arm. If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain steadily lit during the arming process, although the system will still arm. When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for about 3 minutes. Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it means the alarm was activated. Check the vehicle for tampering. Manual Override - The system will not arm if the doors are locked using the manual lock control (by hand) or if the locks are actuated by an inside occupant after the door is closed. When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus to the powertrain control module that it is not OK to start the engine. The powertrain control module then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting down the engine (start and stall condition). The engine will not start until the system is disarmed. To verify the system, proceed as follows: 1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with the power lock switch. 4. Close the driver's door. NOTE: After the doors are closed, locking the doors with RKE will also arm the system. NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may be a problem with the system. System initialization is accomplished by: 1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder to unlock/disarm position. Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming sequence is completed only after all doors are closed. Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with the key). This disarming also will halt the alarm once it has been activated. Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle doors. This disarming also will halt the alarm once it has Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7882 been activated. System Self-Test NOTE: System self-test can be entered only with the DRB. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication with the powertrain control module possibly has been lost. Shipping Mode By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle. The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse. The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will not operate until the IOD is reconnected or the ignition switch is turned to the run/start position. Six-Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation System Coverage These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth Voyager vehicles equipped with either base, midline, or highline body control modules. Airbag Trouble Code Descriptions Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in the airbag section to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with "AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must be performed. If more than one code exists, diagnostic priority should be given to the active code(s). Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes are used as a diagnostic tool. Active Codes An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. Stored Codes An airbag trouble code becomes active and stored as soon as it is detected with the exception of the Loss of Ignition Run Only code, which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7883 malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire harness and connectors. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Diagnostic Trouble Codes The airbag control module may report any of the following diagnostic trouble codes. For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer - AECM Internal Diagnostic 2 - AECM Internal Diagnostic 1 - AECM Output Driver - AECM Stored Energy - Internal Diagnostic 3 - Incorrect AECM For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open - No CCD Communication - Driver Squib Circuit Shorted - Passenger Squib Circuit Open - Driver Squib Term Shorted to Battery - Passenger Squib Circuit Shorted - Driver Squib Term Shorted to Ground - Pass Squib Term Shorted to Battery - Loss of Ignition Run Only - Pass Squib Term Short to Ground - Loss of Ignition Run/Start - Warning Lamp Circuit Open - Output Driver Not Tested - Warning Lamp Circuit Shorted Driver Squib Circuit Open NAME OF CODE Driver Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring open or high resistance in clockspring - Driver side airbag module open - Driver airbag line 1 or line 2 open - Loose or poor connection at connector terminals Driver Squib Circuit Shorted NAME OF CODE Driver Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Clockspring short - Driver side airbag module short Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7884 - Driver airbag line 1 shorted to line 2 - Loose, or poor connector not completely connected Driver Squib Term Shorted to Battery NAME OF CODE Driver Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to voltage - Driver airbag line 2 short to voltage - Faulty clockspring - Faulty airbag control module Driver Squib Term Shorted to Ground NAME OF CODE Driver Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Driver airbag line 1 short to ground potential - Driver airbag line 2 short to ground potential - Faulty clockspring - Faulty airbag control module Loss of Ignition Run Only NAME OF CODE Loss of Ignition Run Only NOTE: This code becomes active as soon as the condition is detected (this is not a stored code). WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Open ignition run circuit - Open fuse - Ignition run circuit short to ground - Loose or poor connection at connector terminals Loss of Ignition Run/Start NAME OF CODE Loss of Ignition Run/Start NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7885 - Open ignition run/start circuit - Open fuse - Ignition run/start circuit short to ground - Loose or poor connection at connector terminals Passenger Squib Circuit Open NAME OF CODE Passenger Squib Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) open - Passenger airbag line 1 or line 2 open - Loose or poor connection at connector terminals Passenger Squib Circuit Shorted NAME OF CODE Passenger Squib Circuit Shorted NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. POSSIBLE CAUSES - Passenger side airbag module (squib) short - Passenger airbag line 1 shorted to line 2 - Loose or poor connection at connector terminals Pass Squib Term Shorted to Battery NAME OF CODE Pass Squib Term Shorted to Battery NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to voltage - Passenger airbag line 2 short to voltage - Faulty airbag control module Pass Squib Term Shorted to Ground NAME OF CODE Pass Squib Term Shorted to Ground NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED Continuously with ignition on. SET CONDITION With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected. POSSIBLE CAUSES - Passenger airbag line 1 short to ground potential Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7886 - Passenger airbag line 2 short to ground potential - Faulty airbag control module Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NAME OF CODE Warning Lamp Circuit Shorted or Warning Lamp Circuit Open NOTE: This code becomes active and stored as soon as the malfunction is detected. WHEN MONITORED With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or during a lamp check. SET CONDITION With the voltage on, the airbag warning lamp driver circuit is other than expected. POSSIBLE CAUSES - Faulty warning lamp - Open fused ignition switch output circuit to Information Center - Airbag warning lamp driver circuit short to ground - Airbag warning lamp driver circuit short to voltage - Faulty information center printed circuit board - Loose or poor connection at connector terminal Output Driver Not Tested NAME OF CODE Output Driver Not Tested WHEN MONITORED At ignition on. SET CONDITION This code may set whenever another code is set due to any short to battery or short to ground failure of the squib circuits. If all other squib codes have been repaired and this code appears active by itself, the problem will be an internal failure of the airbag control module. POSSIBLE CAUSES - Short circuit to ground or to battery in either driver or passenger airbag lines - Defective airbag control module Trouble Code Testing Notes Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes. It is not necessary to perform all of the tests to diagnose an individual code. The body control module will set a diagnostic trouble code if a monitored input is determined to be malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the trouble code condition is removed, the body control module will back out the diagnostic trouble code if the trouble code condition remains cleared for twenty ignition cycles. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This will direct you to the specific test(s) that must be performed. ASB Message Not Received NAME OF CODE ASB Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from CAB every second. If this message is not received by the BCM for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from CAB to BCM Airbag Message Not Received Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7887 NAME OF CODE Airbag Message Not Received WHEN MONITORED Continuously with ignition on. SET CONDITION BCM receives CCD message from ACM every second. It this message is not received by the BCM for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key cycles after the problem is repaired if it is not erased after repair. POSSIBLE CAUSES - No response from ACM to BCM Battery Power to Module Disconnected NAME OF CODE Battery Power to Module Disconnected WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION Battery power to the BCM is disconnected while the ignition is on. THEORY OF OPERATION The body control module checks battery input and determines if the battery is connected. POSSIBLE CAUSES - In shipping mode - IOD fuse missing - Open wire - Blown IOD fuse EATX PRNDL Message Test Failed NAME OF CODE EATX PRNDL Message Test Failed WHEN MONITORED When engine is running. SET CONDITION The engine is running above 450 rpm and the body control module has not received a transmission PRNDL message. THEORY OF OPERATION The body control module will monitor the CCD bus and look for the transmission PRNDL message whenever the engine rpm is above 450. POSSIBLE CAUSES - Body Control module - Transmission control module - CCD bus failure - Loss of power to transmission control module EEPROM Checksum Failure NAME OF CODE EEPROM Checksum Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The sum of EEPROM constants does not equal the correct value. THEORY OF OPERATION By using a checksum, the BCM monitors the value of each programmable constant. The code is set if any value is incorrect. POSSIBLE CAUSES Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7888 - Body Control module Front Wiper Park Switch CKT Open NAME OF CODE Front Wiper Park Switch Ckt Open WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Open wire - Wiper motor - Body Control module Front Wiper Park Switch CKT-Shorted NAME OF CODE Front Wiper Park Switch Ckt-Shorted WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts and wiper motor turned on. SET CONDITION The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned to the park position. THEORY OF OPERATION The BCM interfaces with the front wiper motor and performs wiper functions based upon the input voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park switch and when it returns. When it fails to receive that information, it sets this code. The wiper will run in low speed only and stop whenever the switch is shut off. POSSIBLE CAUSES - Shorted wire - Wiper motor - Body Control module Fuel Level Sending Circuit Error NAME OF CODE Fuel Level Sending Circuit Error WHEN MONITORED With the ignition key on and battery voltage above 10 volts. SET CONDITION When the BCM senses an open or short on the fuel level sensor signal circuit. THEORY OF OPERATION The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be set. POSSIBLE CAUSES - Open wire - Shorted wire - Fuel level sending unit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7889 - Body control module Internal Module Test Failed NAME OF CODE Internal Module Test Failed WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The body control module performs an internal check and determines the body control module is not functioning properly. THEORY OF OPERATION The body control module performs internal diagnostics on demand and determines if the body control module microprocessor is functioning properly. POSSIBLE CAUSES - Body control module Left Door Key CYL Arm SW Failure NAME OF CODE Left Door key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Key CYL Disarm SW Failure NAME OF CODE Left Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left door key cylinder switch - Body control module Left Door Lock Switch Failure NAME OF CODE Left Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7890 SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Left Door Unlock Switch Failure NAME OF CODE Left Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted left front door switch - Body control module Liftgate Key CYL Arm SW Failure NAME OF CODE Liftgate Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Key CYL Disarm SW Failure NAME OF CODE Liftgate Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7891 level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted liftgate key cylinder switch - Body control module Liftgate Door Mux CKT Short to GND NAME OF CODE Liftgate Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (Liftgate Switch MUX) - Body control module LT Front Door Mux Circuit Short to GND NAME OF CODE LT Front Door MUX Circuit Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (LF Door Switch MUX) - Body control module No CCD Message From PCM NAME OF CODE No CCD Message From PCM WHEN MONITORED When the ignition is in the run or start position and battery voltage is above 10 volts. SET CONDITION The BCM looks for engine messages over the CCD bus and does not receive a message within a 2-second period. THEORY OF OPERATION The body control module will monitor the engine messages after the ignition has been turned on. POSSIBLE CAUSES - Body control module - Powertrain control module - CCD Bus failure Rear Wiper Mux Circuit Error NAME OF CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7892 Rear Wiper MUX Circuit Error WHEN MONITORED With the ignition in the run or accessory position and battery voltage above 10 volts. SET CONDITION When the rear wiper MUX circuit senses a voltage above 5.0 volts. THEORY OF OPERATION The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level. The voltage level will determine the wiper function to be performed. That level will be below 5.0 volts. POSSIBLE CAUSES - Circuit shorted to battery - Open CCM ground circuit Right Door Key CYL Arm SW Failure NAME OF CODE Right Door Key Cyl Arm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Key CYL Disarm SW Failure NAME OF CODE Right Door Key Cyl Disarm Sw Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right door key cylinder switch - Body control module Right Door Lock Switch Failure NAME OF CODE Right Door Lock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7893 THEORY OF OPERATION The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module Right Door Unlock Switch Failure NAME OF CODE Right Door Unlock Switch Failure WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer than 8 seconds. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted right front door lock switch - Body control module RT Front Door Mux CKT Short to GND NAME OF CODE RT Front Door MUX Ckt Short to Gnd WHEN MONITORED Anytime battery voltage is above 10 volts and BCM is awake. SET CONDITION The BCM senses a voltage below .4 volts on the RF door switch MUX circuit. THEORY OF OPERATION The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other. Each switch inside the door has a unique resistance value which when activated sends a voltage level to the BCM. The BCM will interpret the different levels and perform the desired function. POSSIBLE CAUSES - Shorted wire (RF Door Switch MUX) - Body control module Horn Switch Failure NAME OF CODE Horn Switch Failure WHEN MONITORED Continuously with battery connected and IOD fuse installed. SET CONDITION The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to cool down. POSSIBLE CAUSES - Shorted horn relay control circuit - Defective horn switch - Defective BCM Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7894 CCD Radio NAME OF CODE CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume Down Switch (Stuck) Preset Switch (Stuck) WHEN MONITORED Anytime ignition is on and voltage is above 10.0 volts. SET CONDITION When a switch is held active for longer than 20 seconds. THEORY OF OPERATION The BCM monitors the control switches for an active condition and performs the required radio function. When a switch is active for longer than 10 seconds, that switch function will be disabled until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be set. POSSIBLE CAUSES - Defective remote control switch - Shorted radio control MUX circuit Vehicle Communication The body system consists of a combination of modules that communicate over the Chrysler Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the operation of vehicle components and circuits is relayed to the appropriate module(s). Each module receives the same information about a component or circuit as the other modules do. This significantly reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses. The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the highest priority, which is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a "voltage divider network". This network consists of some modules with bias and some with termination. Bias is the part of the voltage divider network that places both bus + and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider network and also provides some electromagnetic protection for the bus. NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section. Any of the following bus failure messages may be displayed. Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Airbag System > Page 7895 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Wiper System FRONT The front wiper system provide the driver with normal wipe (low and high speeds), intermittent wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on position and the ignition is turned off, the wiper will continue to run until it reaches its park position. Other front wiper system features: Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay time is doubled to provide a range time of from 1 second to 36 seconds. Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided. Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then releases it, the wiper will continue to run for 2 additional wipe cycles. REAR The rear wiper system provides the driver with continuous, intermittent, and wiper after wash functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the HVAC control. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Body Control Module: Component Tests and General Diagnostics SELF DIAGNOSTIC TEST To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in the odometer windows (about five seconds) then release the buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists the code 999 (End Test) will momentarily appear. INSTRUMENT CLUSTER DTC CHART DTC ..................................................................................................................................................... .................................................... Description 110 ............................................................................... .......................................................................................................... Memory Fault in cluster 111 ..... .............................................................................................................................................................. ................... Calibration fault in cluster 905 ......................................................................................... ................................................................................ No CCD bus messages from TCM 921 .............. .............................................................................................................................................................. ......... Odometer fault from BCM 940 ................................................................................................... ...................................................................... No CCD bus messages from PCM 999 ........................ .............................................................................................................................................................. .................... End of Codes NOTE: For DTC testing see Condition Diagnostic Charts below. CONDITIONS Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Instrument Cluster Diagnosis - Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Speedometer Diagnosis - Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Tachometer Diagnosis - Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Fuel Gauge Diagnosis - Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Temperature Diagnosis - Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Odometer Diagnosis - Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis - Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21) CALIBRATION TEST When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move sequentially through each calibration point. The Calibration Table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III). CLUSTER CALIBRATION TABLE Speedometer ....................................................................................................................................... ................................................. Calibration Point 1 ........................................................................................................................................................... ............................................... 0 mph (0 Km/h) 2 ................................................................................. ..................................................................................................................... 20 mph (40 Km/h) 3 ....... .............................................................................................................................................................. ................................. 55 mph (80 Km/h) 4 ........................................................................................... .......................................................................................................... 75 mph(120 Km/h) Tachometer ......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ............................................................... 0 rpm 2 ................................................................................ .................................................................................................................................... 1000 rpm 3 ..... .............................................................................................................................................................. ................................................. 3000 rpm 4 ........................................................................................ ............................................................................................................................ 6000 rpm Fuel Gauge .......................................................................................................................................... ................................................ Calibration Point 1 ........................................................................................................................................................... ......................................................... Empty(E) 2 ................................................................................. ................................................................................................................................... 1/8 Filled 3 ....... .............................................................................................................................................................. ............................................... 1/4 Filled 4 ........................................................................................... ............................................................................................................................ Full (F) Temperature Gauge ............................................................................................................................ ............................................... Calibration Point 1 ........................................................................................................................................................... .......................................................... Cold (C) 2 ................................................................................. .............................................................................................................................. Low Normal 3 ....... .............................................................................................................................................................. ......................................... High Normal 4 ............................................................................................ ........................................................................................................................... Hot (H) DIM TEST When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays will dim down. If the VF display brightness does Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7898 no change, a problem exists in the cluster. ODOMETER SEGMENT TEST When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally, a problem exists in the display. ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST When CHEC-3 is displayed in the odometer window, each segment of the transmission range indicator will illuminate sequentially. If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display board. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 7899 Body Control Module: Scan Tool Testing and Procedures Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions. DRBIII Error Messages Under normal operation, the DRB will display one of only two error messages: - User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the scantool manufacturer for information and assistance. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 7900 Body Control Module: Service and Repair Body Control Module Location REMOVAL 1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4. Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control Module downward to disengage guide studs on Junction Block from channels on BCM mounting bracket. 8. Remove Body Control Module from Junction Block. INSTALLATION 1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5. Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker reinforcement. 8. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 7901 Body Control Module: Tools and Equipment The following tools are recommended to properly diagnose CCD bus problems: - Scan tool -- with correct cartridge and applicable connectors. - Jumper Wires - Ohmmeter - Oil Pressure Gauge (0-300 psi) - Test Light - Voltmeter Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7910 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7911 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7912 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7913 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7919 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7920 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7921 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7922 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Roll door glass up. 2. Remove the watershield. (Refer to Front Door Panel.) 3. Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. 4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. 5. Disengage clip holding door latch linkage to door latch. 6. Remove latch linkage from latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch. Fig. 19 9. Remove nuts holding outside door handle to door outer panel (Fig. 19). 10. Remove outside door handle from vehicle. INSTALLATION If outside door handle replacement is necessary, transfer lock cylinder from the original handle to the new one. 1. Place outside door handle in position on vehicle. 2. Install nuts attaching outside door handle to door outer panel (Fig. 19) . 3. Insert lock linkage into door latch. 4. Engage ,clip to hold door lock linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to latch. 7. Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch operation. 10. Install sound shield and door trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL 1. Tape the window in its existing position to remove its weight from the regulator system. 2. Cut and remove the tie wrap at the window motor. Its no longer required. 3. Disconnect window motor wire connector from door harness. 4. Remove screws and nuts holding window motor to the inner panel. 5. Remove the motor from the door inner panel, let it hang from the cables. 6. With the cables still attached to the failed motor, Install the replacement motor to the door inner panel. Tighten down the screws and nuts to 3.4 to 4.5 N.m ( 30 to 40 in. lbs.) of torque. 7. Separate the failed motor from regulator by: - Removing the drum cover plate. Power Window Motor Removal - Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously. CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the cables unwind. INSTALLATION 1. Install the cable guide and drum into the replacement motor. CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor shaft by a slight rotation, then, the glass should be lowered a small amount approximately 1 to 2 inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance of a second person. 2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the wiring harness to the window motor connector. 4. Remove the tape holding the window in place and test window operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair Sliding Door Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away from adhesive around perimeter of inner door panel as necessary to access outside release handle fasteners. 4. Remove latch/lock control cover. 5. Disengage clip holding outside door handle linkage to door handle. 6. Remove linkage from outside door handle. 7. Remove linkage from latch/lock control. Fig. 31 8. Remove nuts holding outside door handle to outer door panel (Fig. 31). 9. Remove outside door handle from vehicle. INSTALLATION 1. Position outside door handle on vehicle. 2. Install nuts attaching outside door handle to outer door panel. 3. Insert linkage into outside door handle. 4. Engage clip to hold linkage to outside door handle. 5. Engage rigging-cam to latch/lock control mechanism. 6. Move clip on latch/lock control to bottom of slot and engage linkage to latch/lock control. 7. Verify sliding door operation. Adjust as necessary. 8. Install latch/lock cover. 9. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 10. Install sliding door stop bumper. 11. Install sliding door trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair REMOVAL 1. Remove left quarter trim panel. 2. Remove water shield patch covering access hole in C-pillar. 3. Disengage latch release link from clip on fuel fill blocker latch arm. 4. Open fuel fill door. 5. Remove screws holding fuel fill neck to fuel filler housing. 6. Position fuel fill neck out of the way. 7. Reaching inside fuel filler housing, release clips holding housing to quarter panel. 8. Remove fuel fill door from vehicle. 9. Disengage clip holding link to fuel fill door. 10. Remove link from fuel fill door. INSTALLATION 1. Install spring to housing and door 2. Snap door into housing. 3. Insert lockout link into clip on fuel fill door. 4. Engage clip to hold link to fuel fill door. 5. Insert lockout link through grommet in panel between inner and outer quarter panel. 6. Close fuel fill door. 7. Install fuel filler housing to outer quarter panel. 8. Verify that all clips on fuel filler housing are fully engaged to outer quarter panel. 9. Place fuel fill neck in position. 10. Install screws to hold fuel fill neck to fuel filler housing. 11. Engage latch release link into clip on fuel fill blocker latch arm. 12. Verify fuel fill blocker latch operation. 13. Install water shield patch to cover access hole in C-pillar. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Page 7940 14. Install left quarter trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications To Body Attaching Bolts ...................................................................................................................... ................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12 ............................................................................................................................................ 108 Nm (80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14 .......................................................................................................................................... 166 Nm (123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts ............................................................................................................................................... 165 Nm (123 ft. lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page 7950 Cross-Member: Description and Operation This vehicle uses a one piece cast aluminum cradle for the front suspension. The cradle is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. The cradle is mounted to the front frame rails at four points, two on each side of the vehicle. The cradle is isolated from the body of the vehicle using four isolators, one located at each mounting bolt location. CAUTION: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the cradle that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil thread insert, or equivalent which has been specifically developed for this application. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page 7951 Cross-Member: Service and Repair CAUTION: When performing this procedure use only the thread inserts which are specified in the Mopar (R) Parts Catalog, or equivalent for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. SUSPENSION CRADLE THREAD REPAIR PROCEDURE The threaded holes in the front suspension cradle, if damaged, can repaired by installing a Heli-Coil (R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the suspension crossmember to be repaired, eliminating the need to replace the crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar (R) Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8 x 1.25 and M10 x 1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8 x 1.25 THREAD - 8.3 mm (5/16 inch) Drill Bit - 120° Countersink - Heli-Coil (R) Tap #4863-8 - Heli-Coil (R) Gage #4624-8 - Heli-Coil (R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10 x 1.5 THREAD - 10.5 mm (25/64 inch) Drill Bit - 120° Countersink - Heli-Coil (R) Tap #4863-10 - Heli-Coil (R) Gage #4624-10 - Heli-Coil (R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front Crossmember Subframe: Service and Repair Front Crossmember REMOVAL AND INSTALLATION FRONT CROSSMEMBER The front suspension crossmember must be installed in the design location to achieve proper front end suspension alignment. If the crossmember is removed without applying reference marks on the frame rails, align the crossmember according to the dimensions provided in this group. NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through a Mopar Parts supplier. REMOVAL 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove knee blocker reinforcement. 4. Position steering so front wheels are straight ahead. CAUTION: DO NOT ROTATE STEERING WHEEL AFTER DISENGAGING LOWER COUPLING FROM STEERING GEAR, DAMAGE TO AIRBAG CLOCK SPRING CAN RESULT. Steering Coupling Boot 5. Remove clinch bolt holding steering column coupling to steering gear shaft. 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist and support vehicle on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using hose pinch-off pliers C-4390, pinch power steering oil return hose off between the cross-member coupling and the pump. 10. Loosen hose clamp at the crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump. Remove flare nut holding high pressure hose to back of pump. 13. Separate high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts holding anti-lock brake sensor leads to crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. Refer to Steering and Suspension. 18. Disconnect lower ball joints from lower control arms. Refer to Steering and Suspension. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front Crossmember > Page 7956 Rear Engine Mount 19. Remove bolt holding rear engine mount to crossmember. 20. Using paint or grease pencil, mark outline of crossmember on frame rails to aid installation. Crossmember 21. Support crossmember on suitable lifting device. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front Crossmember > Page 7957 Crossmember Mount 22. Remove bolts holding crossmember to front frame rails. Crossmember 23. Remove crossmember from vehicle. INSTALLATION NOTE: If crossmember requires replacement. Refer to Steering and Suspension, to transfer steering and suspension components. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front Crossmember > Page 7958 Crossmember 1. Support crossmember on suitable lifting device. 2. Position crossmember to vehicle. 3. Loosely install bolts to hold crossmember to front frame rails. 4. Align crossmember to previously made marks on frame rails. 5. Tighten bolts holding crossmember to frame rails. 6. Install bolt holding rear engine mount to cross-member. 7. Connect lower ball joints to lower control arms. Refer to Steering and Suspension. 8. Connect stabilizer bar links to ends of stabilizer bar. Refer to Steering and Suspension 9. Install bolts to hold anti-lock brake sensor leads to crossmember. 10. Install high pressure hose to pump. 11. Connect return hose to metal tube. 12. Tighten hose clamp at the crossmember coupling. 13. Remove pinch-off pliers. 14. Position steering so front wheels are straight ahead. 15. Install steering column coupling to telescoping steering gear shaft. 16. Install clinch bolt to hold steering column coupling to steering gear shaft. 17. Install knee blocker reinforcement. 18. Install steering column lower cover from instrument panel. 19. Connect battery negative cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front Crossmember > Page 7959 Subframe: Service and Repair Front Crossmember Mount Bushings FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of crossmember on frame rails. 2. Loosen bolts holding crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lube or soap to replacement bushing. 2. Insert lower half of bushing into square hole in crossmember. 3. Place upper half of bushing on top of cross-member aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into crossmember and upper bushing. 7. Install bolt to hold bushing and crossmember to frame rail hand tight. 8. Align crossmember to reference marks on frame rails. 9. Tighten crossmember to frame rails attaching bolts to 163 Nm 120 ft. lbs. torque. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 Console: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 Console: Electrical Diagrams Overhead Console (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 Overhead Console (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 Overhead Console (Part 3 Of 3) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7986 Console: Description and Operation SYSTEM OPERATION Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC consists of an electronic module that displays compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC to change mode of operation when the ignition is ON. Examples: Compass/Temperature - Trip odometer (ODO) - Average miles per gallon (ECO) - Instant miles per gallon (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Off The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. Thermometer Engine temperature can increase the displayed temperature. The CMTC is designed to dampen temperature readings when the vehicle is moving at a rate slower than 18 miles per hour. The outside temperature is measured from a sensor mounted in the front of the vehicle. If the temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the temperature display should read SC. If the temperature is less than -40 °C (-40 °F), or the sending line is an open circuit, the display should read 0C. The CMTC will not allow the temperature reading to increase when the vehicle is not moving. Compass The CMTC is self calibrating and usually requires no adjustment. The compass will continuously perform a slow calibration to compensate for small magnetic variations common to any automobile. Uncommon magnetic shifts may be caused by items such as magnetic base antennas, which can permanently alter the magnetic field of the vehicle roof panel. If excessive magnetic field continues for 5 minutes, the compass heading will go blank and only the CAL symbol will illuminate. When this occurs, the vehicle roof panel may require demagnetizing. Refer to the demagnetizing procedure. Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only one or two of the eight possible headings. Although the compass will eventually compensate for this shift, it could take several ignition cycles. The compensation process can be expedited by manually activating the fast calibration routine. Refer to the fast calibrating procedure. This procedure may be performed anytime that the compass appears to be inaccurate. If the calibration data stored in the body control module is not received, the compass will read only NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone through three complete circles without stopping, in an area free of magnetic disturbance. If module displays temperature while the compass is blank, turn off ignition and run self diagnostics then demagnetize the vehicle. After demagnetizing, check compass calibration number, refer to Self Diagnostic Test. If greater than 15, demagnetize again until reading is less than 15. If compass still goes blank after demagnetizing then check internal diagnostics and demagnetize. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Page 7987 Universal Transmitter Location Universal Transmitter The Universal Transmitter, replaces the hand held remote controls that open the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the activator codes for up to three remote controlled devices. It triggers those devices at the push of a button, located in a unit permanently mounted in your overhead console (if equipped). The transmitter operates off your vehicle's battery and charging system; no batteries are needed. The Universal Transmitter incorporates a Rolling Code technology (random digital code signals from the remote transmitter) within the transmitter module. This is done so, as an added security measure. Features of the Universal Transmitter are: Can be used with most other Radio Frequency (RF) activated devices. - Individual channels can be trained. - Stores transmitter data in permanent memory - retraining is not required even if the battery dies or is disconnected. To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light up while the signal is being transmitted. NOTE: For security reasons, you are able to erase the trained frequencies. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement Console: Service and Repair Console Replacement REMOVAL Lower Console 1. Remove screws holding lower console to floor bracket and instrument panel. 2. Slide console rearward from around instrument panel supports. 3. Remove lower console. INSTALLATION 1. Place lower console in position. 2. Slide console forward around instrument panel supports. 3. Install screws to hold lower console to floor bracket and instrument panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 7990 Console: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb REMOVAL 1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading lamp bulb socket one quarter turn counter clockwise. Reading/Courtesy Lamp 3. Pull socket out of lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens onto lamp lens pivots. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Replacement > Page 7991 Console: Service and Repair Overhead Console Replacement REMOVAL Overhead Console 1. Open the transmitter bin door. 2. Remove screw holding the overhead console to the headliner. - With the screw removed the console is retained by one engagement tab located inside the eyeglass storage bin. 3. Open the eyeglass bin door. 4. Press the retaining tab which is located directly above the door latch. 5. Lower rear of console away from headliner. 6. Pull console rearward to disengage clips holding front of console to roof armature and lower console. 7. Disconnect wire connectors from back of CMTC and reading lamps. - Ensure the connectors lock tabs are fully depressed before disconnecting. 8. Remove overhead console. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 7992 Degausser 6029 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7999 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Convenience Bin Track Drink Holders: Service and Repair Convenience Bin Track Convenience Bin Access Cover REMOVAL 1. Remove the convenience bin track from the instrument panel or the ash receiver, if equipped. 2. Remove the screw access cover from the bottom of the radio bezel. 3. Remove the center bezel. Convenience Bin Access Cover 4. Remove the convenience bin track attaching screws and pull the convenience bin track rearward to disengage the rear guide studs from instrument panel. 5. Disengage the clip holding convenience bin lamp to track. 6. Remove the convenience bin. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Convenience Bin Track > Page 8004 Drink Holders: Service and Repair Convenience Bin Lamp Unused Convenience Bin Lamp Socket Location If the lamp is not used refer to -- Wiring For The Convenience Lamp. REMOVAL 1. Pull out the convenience bin cup holder. 2. Insert the trim stick between access cover above cup holder and center console. Convenience Bin Access Cover 3. Carefully pry the access cover from the center console. 4. Separate the access cover from the vehicle. 5. Using needle-nose pliers, carefully squeeze the vertical metal legs of the lamp hood. 6. Lift the lamp hood upward from the cup holder tray Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Convenience Bin Track > Page 8005 Convenience Bin Lamp Bulb 7. Carefully pull the lamp and wiring rearward from the instrument panel. 8. Pull the lamp hood from the lamp socket. 9. Pull bulb from socket. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Convenience Bin Track > Page 8006 Drink Holders: Service and Repair Convenience Bin - Cup Holder Ash Receiver - Cup Holder REMOVAL 1. Pull the convenience bin open. 2. Push lock tab at rear center downward. 3. Pull the convenience bin - cup holder from track in instrument panel. 4. Remove convenience bin - cup holder. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair Glove Compartment Lock: Service and Repair REMOVAL Glove Box Lamp Striker 1. Open glove box door. 2. Disengage clip holding check straps to glove box door. 3. Remove screws holding lock striker to instrument panel. 4. Remove glove box lock striker. INSTALLATION 1. Install glove box lock striker. 2. Install screws holding lock striker to instrument panel. 3. Engage clip holding check straps to glove box door. Glove Box Lamp Striker 4. Close glove box door. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair REMOVAL 1. Using a trim stick (C-4755), pry courtesy lamp from door trim. 2. Disconnect wire connector from courtesy lamp. 3. If equipped, remove screws attaching door assist handle to inner door panel. 4. If equipped, remove screw attaching door pull cup to inner door panel. 5. If equipped, remove screws attaching trim panel to door from below map pocket. 6. If equipped, remove window crank. 7. Using a trim stick, remove screw cover from switch panel. 8. Remove screws attaching switch panel to door trim. Fig.32 Front Door Switch Panel 9. Remove power accessary switch from door trim. 10. Disconnect power switch from wire connector. Fig.33 Memory Seat/Mirror Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 8014 11. If equipped, using a small, flat bladed pry tool, remove memory seat/mirror switch and disconnect wire connector. 12. If equipped, remove screw holding door trim to door panel from behind inside latch release handle. Fig.34 Front Door Trim Panel 13. Disengage clips attaching door trim to door frame around perimeter of panel. 14. Lift trim panel upward to disengage flange from inner belt molding at top of door. 15. Tilt top of trim panel away from door to gain access to latch linkage. Fig.35 Inside Door Handle Linkage 16. Disengage clip attaching linkage rod to inside latch release handle. 17. Separate linkage rod from latch handle. 18. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 8015 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8021 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8022 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8023 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > Page 8038 Keyless Entry Transmitter Battery: Application and ID The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound Power Door Lock Actuator: Customer Interest Sliding Door Power Lock Actuator - Chatter Sound NUMBER: 23-042-00 GROUP: Body DATE: Nov. 3, 2000 SUBJECT: Sliding Door Power Lock Actuator Chatter Sound OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to eliminate the plunger lifting away from the lock lever when in the lock position. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power lock feature is repeatedly activated. DIAGNOSIS: Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair Procedure. NOTE: REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the 2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and available on MDS2). 2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control. 3. Remove the latch/lock control cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 8048 4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA. 5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator grommet as shown in (Fig. 1). 6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should be heard from the actuator and the plunger should remain held under the lock lever during and after actuation. 7. Install the latch/lock control cover. 8. Install the water shield. 9. Install the sliding door interior trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-03-99 > Feb > 99 > Power Door Lock Motor - Whirling Noise Power Door Lock Actuator: Customer Interest Power Door Lock Motor - Whirling Noise NUMBER: 23-03-99 GROUP: Body DATE: Feb. 12, 1999 SUBJECT: Power Door Lock Motor Whirling Noise MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to help improve Fix It Right (FIR) scores. 1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking to discover any power door lock motors that make a whirling noise, even intermittently. 2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise by placing your ear near the rear of the suspect front door, then activate the power door locks to confirm which side the whirling noise is coming from. 3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors open) and activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door. (leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor Operation Time Schedule for operation number, time allowance and failure code. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound Power Door Lock Actuator: All Technical Service Bulletins Sliding Door Power Lock Actuator Chatter Sound NUMBER: 23-042-00 GROUP: Body DATE: Nov. 3, 2000 SUBJECT: Sliding Door Power Lock Actuator Chatter Sound OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to eliminate the plunger lifting away from the lock lever when in the lock position. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Markets) SYMPTOM/CONDITION: A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power lock feature is repeatedly activated. DIAGNOSIS: Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair Procedure. NOTE: REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS. PARTS REQUIRED: REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the 2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and available on MDS2). 2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control. 3. Remove the latch/lock control cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov > 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 8058 4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA. 5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator grommet as shown in (Fig. 1). 6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should be heard from the actuator and the plunger should remain held under the lock lever during and after actuation. 7. Install the latch/lock control cover. 8. Install the water shield. 9. Install the sliding door interior trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-03-99 > Feb > 99 > Power Door Lock Motor - Whirling Noise Power Door Lock Actuator: All Technical Service Bulletins Power Door Lock Motor - Whirling Noise NUMBER: 23-03-99 GROUP: Body DATE: Feb. 12, 1999 SUBJECT: Power Door Lock Motor Whirling Noise MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to help improve Fix It Right (FIR) scores. 1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking to discover any power door lock motors that make a whirling noise, even intermittently. 2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise by placing your ear near the rear of the suspect front door, then activate the power door locks to confirm which side the whirling noise is coming from. 3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors open) and activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. 6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door. (leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and then a minimum of five times repeatedly unlocking. 7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual. POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor Operation Time Schedule for operation number, time allowance and failure code. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 8063 Power Door Lock Actuator: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 8064 Power Door Lock Actuator: Testing and Inspection Verify battery condition before testing door lock motor(s). To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem may be caused by a shorted motor, a relay or a bad switch. Disconnecting the defective motor will allow the others to work. Door Lock Motor Connector Pin Location Front Door Lock Motor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 8065 Lift Gate Release Assembly To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a 12 Volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are NOT obtained, replace the motor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Lock Motor Power Door Lock Actuator: Service and Repair Liftgate Lock Motor REMOVAL 1. Remove liftgate trim panel. Liftgate Lock Motor 2. Remove bolts holding liftgate lock motor to lift-gate. 3. Disconnect the wire connector from power lock motor. 4. Disconnect the liftgate lock motor from outside handle lock link. 5. Remove the liftgate lock motor from vehicle. INSTALLATION 1. Install the liftgate lock motor from vehicle. 2. Connect the liftgate lock motor from outside handle lock link. 3. Connect the wire connector from power lock motor. Liftgate Lock Motor 4. Install bolts holding liftgate lock motor to lift-gate. 5. Install liftgate trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Lock Motor > Page 8068 Power Door Lock Actuator: Service and Repair Sliding Door Lock Motor REMOVAL 1. Remove sliding door trim panel. 2. Remove watershield as necessary 3. Remove latch/lock control cover. 4. Remove latch/lock control. Sliding Door Lock Motor 5. Remove screws holding door lock motor to latch/lock control. 6. Remove lock motor from control. INSTALLATION 1. Install lock motor from control. Sliding Door Lock Motor 2. Install screws holding door lock motor to latch/lock control. 3. Install latch/lock control. 4. Install latch/lock control cover. 5. Install watershield as necessary Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Liftgate Lock Motor > Page 8069 6. Install sliding door trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection 1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation Heated Element: Description and Operation SYSTEM OPERATION Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description and Operation > Page 8080 Heated Element: Testing and Inspection Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only The heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the rear window defogger is ON. 1. The mirror should be warm to the touch. 2. If not, check the 10 amp fuse (12) in the junction block behind the instrument panel to the left of the steering column. 3. Test voltage at rear window defogger switch. - If no voltage repair wire. Power Mirror Test - Apply voltage to one wire and ground the other, refer for pin numbers. Mirror should become warm to the touch. - If not remove mirror glass and test the wires for continuity If no continuity repair wires. - If wires are OK, replace mirror glass. - To test defogger switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation Seat Memory Switch: Description and Operation SYSTEM OPERATION Memory Selector Switches The memory selector switches are mounted on the driver's door trim panel within easy reach of the driver. They provide a means to set or recall either of two positions of seat and recliner, and the side view mirrors as chosen by the driver. The inputs from these switches to the memory seat/mirror module is a ground level signal. 1. Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press any switches for 10 seconds. 4. To program the second driver's position, follow the above sequence. 5. To recall either of the programmed positions momentarily press and release either memory selector switch 1 or 2. Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 8085 Seat Memory Switch: Testing and Inspection To test the memory selector switch: 1. Remove the memory selector switch. Refer to removal procedure. Memory Selector Switch Continuity 2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 8086 Seat Memory Switch: Service and Repair REMOVAL 1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel. 2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and Inspection Power Mirror Motor: Testing and Inspection 1. Remove headlamp switch bezel. 2. Disconnect wiring harness connector to the power mirror switch and headlamp switch. 3. Using two jumper wires: - Connect one to a 12-Volt source - Connect the other to a good body ground Power Mirror Test - Refer to the Mirror Test Chart for wire hookups at the switch connector. 4. If results shown in chart are not obtained, check for broken or shorted circuit, or replace mirror assembly as necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror/Window Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test Power Mirror Switch: Testing and Inspection Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test > Page 8095 Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck The mirror switches in the instrument panel have normally open contacts when in their inactive state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it then becomes connected to the P73/P70, circuits which are the mirror motor common connections. No faults will result from this action by itself. If one of the other switch contacts from the round portion of the switch becomes accidentally closed, It can cause problems such as both mirrors operating at the same time in the vertical or horizontal modes. Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the closed position, and the left/right portion is actuated to either side, a mirror motor will become actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this condition. - With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in the closed position, the mirror motor will not become actuated. During an ignition switch recall of a driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only if: - The closed switch contact was the same as the desired direction - Until the lack of a signal seen by the module shuts off the drive to the motor The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a single stuck contact could place an opposite mirror or direction into a series connection. This would run the connected motors at approximately half speed. Replace the mirror switch assembly to correct this condition. Mirror Mechanization Mirror Mechanization Table The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror mechanization show that both mirrors use the same functions. The rheostat for position sensing utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D and F. The ground return wire, E, stands alone. The mirror motors for each side use a common connection, B, which becomes automatically connected to the proper polarity power connection during either manual (through the mirror switch) or recall (through the Memory Seat/Mirror Module) modes of operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch Power Mirror Switch REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from headlamp switch bezel. 5. Remove power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 8098 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp Power Mirror Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3. Pull bulb socket from back of power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 8103 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 8104 Keyless Entry Module: Adjustments 1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and before ten seconds passes, press and release the PANIC button. A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code(s). 6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30 seconds or when ignition switch is turned OFF, the RKE module will end the programming mode. A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Code(s). 7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position and verify RKE system operation using each key fob. NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror systems. If a primary key fob is being replaced, the memory seat and mirror module will require programming. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 8105 Keyless Entry Module: Service and Repair REMOVAL 1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel. RKE Module 3. Disconnect wire connector from RKE module. 4. Remove the RKE module. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 8116 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 8117 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-14-98 > Apr > 98 > Roof Rack Rattles at Highway Speeds Roof Rack Frame: Customer Interest Roof Rack - Rattles at Highway Speeds NO: 23-14-98 GROUP: Body DATE: Apr. 24, 1998 SUBJECT: Roof Rack Rattles At Highway Speeds MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Roof rack rattles at speeds above 65 mph (105 kph). The rattle may be heard at slower vehicle speeds when operating the vehicle in strong crosswinds or headwinds. Rough road surfaces DO NOT have an effect on this condition. DIAGNOSIS: If the vehicle operator describes the above condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing revised roof rack crossrails. 1. Using the procedure outlined on page 23-51 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) remove the roof rack crossrail and stanchion assemblies. 2. Separate the stanchions from the crossrails and discard the crossrails. 3. Install the stanchions onto the revised crossrails. 4. Using the procedure outlined on page 23-52 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) install the roof rack crossrail and stanchion assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-06-10-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-14-98 > Apr > 98 > Roof Rack - Rattles at Highway Speeds Roof Rack Frame: All Technical Service Bulletins Roof Rack - Rattles at Highway Speeds NO: 23-14-98 GROUP: Body DATE: Apr. 24, 1998 SUBJECT: Roof Rack Rattles At Highway Speeds MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Roof rack rattles at speeds above 65 mph (105 kph). The rattle may be heard at slower vehicle speeds when operating the vehicle in strong crosswinds or headwinds. Rough road surfaces DO NOT have an effect on this condition. DIAGNOSIS: If the vehicle operator describes the above condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: This bulletin involves installing revised roof rack crossrails. 1. Using the procedure outlined on page 23-51 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) remove the roof rack crossrail and stanchion assemblies. 2. Separate the stanchions from the crossrails and discard the crossrails. 3. Install the stanchions onto the revised crossrails. 4. Using the procedure outlined on page 23-52 of the 1998 Town & Country, Caravan and Voyager service manual (Publication No. 81-370-8105) install the roof rack crossrail and stanchion assemblies. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-06-10-91 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time NUMBER: 23-008-00 Rev. B GROUP: Body DATE: Nov. 24, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS. SUBJECT: Child Seat Tether Anchors MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 2000 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1993 (AJ) Lebaron Coupe 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2000 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1988 - 1992 (BB) Monaco/Premier 1990 - 1994 (BD) Laser/Talon 1994 - 2001 (BR/BE) Ram Truck 1989 - 1992 (B2) Colt/Summit 1992 - 1995 (B3) Colt Vista 1989 (B5) Conquest 1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada) 1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon 1993 - 1994 (B9) Colt/Summit 1998 - 2000 (DN) Durango 1995 - 1999 (FJ) Sebring/Avenger/Talon 1995 - 1999 JA Cirrus/Stratus/Breeze 1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2000 (PL) Neon 1997 - 1999 (PR) Prowler 1996 - 1999 (SR) Viper/Viper GTS **2000 (TJ) Wrangler** 1999 - 2000 (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS. DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8137 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8138 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8139 PARTS REQUIRED: POLICY: Customer Satisfaction Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8140 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins > Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8141 TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation Seat Memory Switch: Description and Operation SYSTEM OPERATION Memory Selector Switches The memory selector switches are mounted on the driver's door trim panel within easy reach of the driver. They provide a means to set or recall either of two positions of seat and recliner, and the side view mirrors as chosen by the driver. The inputs from these switches to the memory seat/mirror module is a ground level signal. 1. Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press any switches for 10 seconds. 4. To program the second driver's position, follow the above sequence. 5. To recall either of the programmed positions momentarily press and release either memory selector switch 1 or 2. Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 8146 Seat Memory Switch: Testing and Inspection To test the memory selector switch: 1. Remove the memory selector switch. Refer to removal procedure. Memory Selector Switch Continuity 2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Description and Operation > Page 8147 Seat Memory Switch: Service and Repair REMOVAL 1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel. 2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range NO: 08-44-98 GROUP: Electrical DATE: Dec. 11, 1998 SUBJECT: Memory Power Seat Travel Range MODELS: 1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand Cherokee 1996-1998 (ZG) Grand Cherokee (International Market) DISCUSSION: The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the motor end, fails to change. The feedback voltage potentiometers vary the position sensing feedback voltage based on seat position/movement (no movement, no change in position sensing feedback voltage). The seat motor automatically stops at the soft stop on any subsequent movement so the motor does not run into a stall condition (end of travel). The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when something is stuck under or behind the seat that causes the seat to stop moving). These soft stops can prevent the seat from being able to have memory positions set over the full range of travel. Also, positions that were previously programmed to locations beyond an updated soft stop limit will not be recalled as they are "out of range." When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat operation. There are two potential reasons for intermittent memory functioning of the seats. The first possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in the seat's path or a person shifting their body while a power seat motor is in operation.) The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can be caused by a poor connection at pin 23 of the P34 connector which is located near the right side of the steering column. This circuit is used to communicate and control the seat module. This circuit "locks out" movement when the vehicle is not in park and also causes seat position recall when used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for fully seated and clean contacts. To check and reset the soft stop limits in memory, use the control switches on the side of the seat to move the seat in one direction to the end of travel, then energize the seat again in the same direction until it stops and for three additional seconds after it stops. The amount that the seat moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat this procedure for each of the directions of movement (one at a time). NOTE: IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM (AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE MANUAL). POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and Inspection Power Seat Motor: Testing and Inspection 1. Remove power seat switch from seat 2. Disconnect wire connector. 3. Using a voltmeter check for battery voltage at Pin 5. Using an ohmmeter, check Pin 1 for ground. Seat Motor Test 4. To test the seat motors, refer to and verify proper seat responses. Using two jumper wires, connect one to a battery supply and the other to a ground. Connect the other ends to the seat wire harness connector as described. If any motor fails to operate, check wire connectors to the motor. If not OK, repair as necessary If OK, replace seat motor/track assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward - Seat Front Down - Seat Rear Down - Recliner Rearward - Seat Track Forward - Seat Front Up - Seat Rear Up - Recliner Forward The inputs from these switches to the MSM Module is a current limited battery source fed by the MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All of these switch contact inputs to the module are normally closed to ground, except when actuated. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 8158 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from seat. Power Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise Seat Back: Customer Interest Driver's Side Seat Back - Creak Noise NO:23-69-97 GROUP: Body DATE: Dec. 19, 1997 SUBJECT: Seat Back Creak Noise - Driver's Side MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ADJUSTABLE LUMBAR DRIVER'S SEAT. SYMPTOM/CONDITION: A creaking sound is heard when pressure is applied to and removed from the lumbar area of the driver's seat. DIAGNOSIS: Actuate the lumbar adjustment to the fully extended position. Apply pressure to the front of the seat back in the lumbar area and listen for a creaking noise. If a creaking noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR (1) 0SF471C3AA Back, Seat - (Trim Code H7 or E5) Gray AR (1) 0SF471K5AA Back, Seat - (Trim Code H7 or E5) Camel AR (1) 0SF471JKAA Back, Seat - (Trim Code H7 or E5) Silver Fern AR (1) 0SF491C3AA Back, Seat - (Trim Code XL) Gray AR (1) 0SF491K5AA Back, Seat - (Trim Code XL) Camel AR (1) 0SF511C3AA Back, Seat - (Trim Code XL Heated) Gray AR (1) 0SF511K5AA Back, Seat - (Trim Code XL Heated) Camel AR (1) 0SF531C3AA Back, Seat - (Trim Code FL) Gray AR (1) 0SF531K5AA Back, Seat - (Trim Code FL) Camel REPAIR PROCEDURE: This bulletin involves replacing the driver's seat back. 1. Remove the driver's seat headrest. 2. Remove the armrest. 3. Remove the seat back recliner lever. 4. Remove the lumbar adjustment lever. 5. Remove both seat cushion side covers. 6. Remove nut attaching the recliner to the seat back frame. 7. Remove both pivot bolts and separate the seat back from the recliner. 8. Place the mounting stud of the revised seat back (specified in the Parts Required section) into the recliner. 9. Install the pivot bolts and torque to 30-50 ft. lbs. (41-67 Nm). 10. Install the nut attaching the recliner to the seat back frame and torque to 85-125 in. lbs. (10-14 Nm). 11. Install both seat cushion side covers. 12. Install the lumbar adjustment lever. 13. Install the seat back recliner lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > Customer Interest: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise > Page 8167 14. Install the armrest. 15. Install the driver's seat headrest. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-96 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise Seat Back: All Technical Service Bulletins Driver's Side Seat Back - Creak Noise NO:23-69-97 GROUP: Body DATE: Dec. 19, 1997 SUBJECT: Seat Back Creak Noise - Driver's Side MODELS: 1998 (NS) Town & Country/Caravan/Voyager NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ADJUSTABLE LUMBAR DRIVER'S SEAT. SYMPTOM/CONDITION: A creaking sound is heard when pressure is applied to and removed from the lumbar area of the driver's seat. DIAGNOSIS: Actuate the lumbar adjustment to the fully extended position. Apply pressure to the front of the seat back in the lumbar area and listen for a creaking noise. If a creaking noise is heard, perform the Repair Procedure. PARTS REQUIRED: AR (1) 0SF471C3AA Back, Seat - (Trim Code H7 or E5) Gray AR (1) 0SF471K5AA Back, Seat - (Trim Code H7 or E5) Camel AR (1) 0SF471JKAA Back, Seat - (Trim Code H7 or E5) Silver Fern AR (1) 0SF491C3AA Back, Seat - (Trim Code XL) Gray AR (1) 0SF491K5AA Back, Seat - (Trim Code XL) Camel AR (1) 0SF511C3AA Back, Seat - (Trim Code XL Heated) Gray AR (1) 0SF511K5AA Back, Seat - (Trim Code XL Heated) Camel AR (1) 0SF531C3AA Back, Seat - (Trim Code FL) Gray AR (1) 0SF531K5AA Back, Seat - (Trim Code FL) Camel REPAIR PROCEDURE: This bulletin involves replacing the driver's seat back. 1. Remove the driver's seat headrest. 2. Remove the armrest. 3. Remove the seat back recliner lever. 4. Remove the lumbar adjustment lever. 5. Remove both seat cushion side covers. 6. Remove nut attaching the recliner to the seat back frame. 7. Remove both pivot bolts and separate the seat back from the recliner. 8. Place the mounting stud of the revised seat back (specified in the Parts Required section) into the recliner. 9. Install the pivot bolts and torque to 30-50 ft. lbs. (41-67 Nm). 10. Install the nut attaching the recliner to the seat back frame and torque to 85-125 in. lbs. (10-14 Nm). 11. Install both seat cushion side covers. 12. Install the lumbar adjustment lever. 13. Install the seat back recliner lever. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise > Page 8173 14. Install the armrest. 15. Install the driver's seat headrest. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-20-32-96 0.6 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Back: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature Battery Failure NO: 08-39-97 GROUP: Electrical DATE: Nov. 28, 1997 SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely MODELS: 1997 - 1998 (AB) Ram Van/Wagon 1997 - 1998 (AN) Dakota/Dakota Cab & Chassis 1998 (BRIBE)Ram Truck 1998 (DN) Durango 1997 (LH) Concorde/Intrepid/LHS/Vision 1997 - 1998 (NS) Town & Country/Caravan/Voyager 1997 - 1998 (PL) Neon 1997 (PR) Prowler 1997 - 1998 (ZJ) Grand Cherokee NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX). SYMPTOM/CONDITION: Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH 0815XX, perform the Repair Procedure. PARTS REQUIRED: AR 04686366 Transmitter, RKE- NS, PL & PR AR 04759136AB Transmitter, RKE- LH AR 56007049 Transmitter, RKE- AB & 1997 AN AR 56008761 Transmitter 1, RKE- ZJ & DN AR 56008762 Transmitter 2, RKE- ZJ AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN REPAIR PROCEDURE: This bulletin involves replacing the RKE transmitter(s). 1. Replace RKE transmitter(s) that have discharged batteries. 2. Program the RKE transmitter(s) to the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-80-28-93 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions Seat Heater: Technical Service Bulletins Interior - Seat Heater Service Manual Revisions NUMBER: 26-04-98C GROUP: Miscellaneous DATE: April, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN MODELS: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revisions to the electrically heated Systems section Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8188 8N-1 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8189 8N-2 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8190 8N-3 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8191 8N-4 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8192 8N-5 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8193 8N-6 POLICY: Information Only Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8194 Seat Heater: Technical Service Bulletins Interior - Seat Heater Harness Location Revision NUMBER: 26-04-99G GROUP: Miscellaneous DATE: April, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number 81-370-8105 DESCRIPTION OF CHANGES Revision to the Electrically Heated Seat harness location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8195 8N-4 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 8196 Seat Heater: Description and Operation The content of this article reflects the changes called out by TSB 26-04-99. INTRODUCTION Individually controlled electrically heated front seats are available factory-installed optional equipment. The seat heaters will only operate when the ignition switch is in the On position, and the surface temperature at the front seat heating element sensors is below the designed temperature set points of the system. The heated seat system will not operate in ambient temperatures greater than about 32 °C (90 °F). There are separate three-position switches for each front seat located in the inboard seat cushion side shield. An Off, Low, or High position can be selected with each switch, and Light-Emitting Diodes (LED) for each switch illuminate to give a visual indication that the system is turned on. The Low heat position set point is about 32 °C (90 °F), and the High heat position set point is about 38 °C (100 °F). Each switch controls a Heated Seat Control Module (HSCM) mounted to the seat cushion frame under each front seat. When a seat heater is turned on, a sensor located near the seat cushion electric heater element provides the HSCM with an input indicating the surface temperature of the seat cushion. If the surface temperature input is below the temperature set point for the selected Low or High switch position, a relay within the HSCM energizes the heating elements in the seat cushion and back. When the sensor input indicates the correct temperature set point has been achieved, the HSCM de-energizes the relay The HSCM will continue to cycle the relay as needed to maintain the temperature set point. The HSCM will automatically turn off the heating elements if it detects an open in the sensor circuit, or a short in the heating element circuit causing an excessive current draw. The system is also turned off automatically when the ignition switch is turned to the Off position. The control circuit operates on ignition switched battery feed through a fuse in the junction block. The heating elements operate on battery feed supplied through the power seat circuit breaker located in the wire harness under the driver's seat. SYSTEM OPERATION Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat, one for the seat cushion and the other for the seat back. The two element for each seat are connected in series with the HSCM. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is integrated into the seat cushion heating element. The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which are serviced individually. The heating elements and temperature sensor cannot be repaired and, if faulty or damaged, the affected seat cover assembly must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System Seat Heater: Testing and Inspection Heated Seat System Before testing the individual components in the heated seat system, check the following: - If the heated seat switch LED doesn't light with the ignition switch in the On position and the heated seat switch in the Low or High position, check the fuse in the junction block. If the Fuse is OK, test the heated seat switch as described. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. - If the heated seat switch LED lights, but the heating elements don't heat, check the circuit breaker in the junction block. If the circuit breaker is OK, test the heated seat elements as described. If not OK, replace the faulty circuit breaker. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat System > Page 8199 Seat Heater: Testing and Inspection Heated Seat Element The wire harness connectors for the seat cushion and seat back heating elements are located under the seat, near the rear edge of the seat cushion frame. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation SYSTEM OPERATION The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate the electric seat heater elements. Two modules are used in the vehicle, one for each front seat. The HSCM for each seat is installed on front portion of each cushion pan. The wire harness connector is secured by an integral clip to the inside surface of the outboard seat cushion frame. Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery feed, and a ground. The only HSCM output is the feed for the seat heating elements. The HSCM cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 8203 Seat Heater Control Module: Testing and Inspection Before testing the heated seat control module, test the heated seat switch, the heated seat elements, and the heated seat sensor as described. If testing of the heated seat switch, elements, and sensor reveals no problems, proceed as follows. 1. Replace the heated seat control module with a known good unit and test the operation of the heated seats. If OK, discard the faulty heated seat control module. If not OK, go to Step 2. 2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat sensor to the heated seat control module. Repair any short or open circuits as required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 8204 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5. Remove module from seat cushion pan. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 8208 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 8209 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation Seat Heater Thermostat: Description and Operation SYSTEM OPERATION Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat, one for the seat cushion and the other for the seat back. The two element for each seat are connected in series with the HSCM. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is integrated into the seat cushion heating element. The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which are serviced individually. The heating elements and temperature sensor cannot be repaired and, if faulty or damaged, the affected seat cover assembly must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description and Operation > Page 8213 Seat Heater Thermostat: Testing and Inspection The wire harness connector for the seat cushion heating element and sensor are located under the seat, near the rear edge of the seat cushion frame. 1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire harness connector. 2. Using an ohmmeter, check the resistance between the heated seat switch output circuit cavity and the ground circuit cavity of the seat cushion cover half of the heated seat cushion wire harness connector. The sensor resistance should be between 2 kilo ohms and 200 kilo ohms. If OK, test the heated seat control module as described. If not OK, replace the faulty seat cushion cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles Seat Latch: Customer Interest Quad Seat Easy Entry Latch - Rattles NUMBER: 23-27-99 GROUP: Body DATE: Jul. 23, 1999 SUBJECT: Quad Seat Easy Entry Latch Rattle OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: Rattle noise is heard when driving DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure. PARTS REQUIRED: 1 04773968 Tape, Flock 1 04318063 Grease REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the mylar tape from the easy entry latch striker (Fig. 1) 2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with isopropyl alcohol. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 8222 3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2). 4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker. 5. Return the quad seat to its latched/normal position. 6. Repeat for the other quad seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles Seat Latch: All Technical Service Bulletins Quad Seat Easy Entry Latch - Rattles NUMBER: 23-27-99 GROUP: Body DATE: Jul. 23, 1999 SUBJECT: Quad Seat Easy Entry Latch Rattle OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch. MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: Rattle noise is heard when driving DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure. PARTS REQUIRED: 1 04773968 Tape, Flock 1 04318063 Grease REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the mylar tape from the easy entry latch striker (Fig. 1) 2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with isopropyl alcohol. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 8228 3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2). 4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker. 5. Return the quad seat to its latched/normal position. 6. Repeat for the other quad seat. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs. FAILURE CODE: AM - Authorized Modification Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair Hood Sensor/Switch (For Alarm): Service and Repair REMOVAL 1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger switch from top of the radiator closure panel. Hood Ajar Switch 3. Disconnect the trigger switch from the wire connector and remove the switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection Power Door Lock Switch: Testing and Inspection 1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror/Window Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test Power Mirror Switch: Testing and Inspection Mirror Switch Test 1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch connector. Mirror Switch Test 3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Mirror Switch Test > Page 8242 Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck The mirror switches in the instrument panel have normally open contacts when in their inactive state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it then becomes connected to the P73/P70, circuits which are the mirror motor common connections. No faults will result from this action by itself. If one of the other switch contacts from the round portion of the switch becomes accidentally closed, It can cause problems such as both mirrors operating at the same time in the vertical or horizontal modes. Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the closed position, and the left/right portion is actuated to either side, a mirror motor will become actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this condition. - With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in the closed position, the mirror motor will not become actuated. During an ignition switch recall of a driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only if: - The closed switch contact was the same as the desired direction - Until the lack of a signal seen by the module shuts off the drive to the motor The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a single stuck contact could place an opposite mirror or direction into a series connection. This would run the connected motors at approximately half speed. Replace the mirror switch assembly to correct this condition. Mirror Mechanization Mirror Mechanization Table The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror mechanization show that both mirrors use the same functions. The rheostat for position sensing utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D and F. The ground return wire, E, stands alone. The mirror motors for each side use a common connection, B, which becomes automatically connected to the proper polarity power connection during either manual (through the mirror switch) or recall (through the Memory Seat/Mirror Module) modes of operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch Power Mirror Switch: Service and Repair Power Mirror Switch Power Mirror Switch REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from headlamp switch bezel. 5. Remove power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch > Page 8245 Power Mirror Switch: Service and Repair Power Mirror Switch Lamp Power Mirror Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3. Pull bulb socket from back of power mirror switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward - Seat Front Down - Seat Rear Down - Recliner Rearward - Seat Track Forward - Seat Front Up - Seat Rear Up - Recliner Forward The inputs from these switches to the MSM Module is a current limited battery source fed by the MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All of these switch contact inputs to the module are normally closed to ground, except when actuated. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 8249 Power Seat Switch: Testing and Inspection 1. Remove power seat switch from seat. Power Seat Switch Test 2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the switch positions, replace switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation SYSTEM OPERATION The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If either switch or LED is faulty, the switch must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 8253 Seat Heater Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion side cover. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output circuit cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position, disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open circuit as required. 4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK, replace the faulty switch. 5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance between the fused ignition switch output circuit terminal and the heated seat switch output circuit terminal in the connector receptacle on the back of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 8254 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755), gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out switch from rear of switch bezel. 5. Remove switch from bezel. INSTALLATION For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation Seat Memory Switch: Description and Operation SYSTEM OPERATION Memory Selector Switches The memory selector switches are mounted on the driver's door trim panel within easy reach of the driver. They provide a means to set or recall either of two positions of seat and recliner, and the side view mirrors as chosen by the driver. The inputs from these switches to the memory seat/mirror module is a ground level signal. 1. Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press any switches for 10 seconds. 4. To program the second driver's position, follow the above sequence. 5. To recall either of the programmed positions momentarily press and release either memory selector switch 1 or 2. Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must be met for proper operation of the system. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Page 8258 Seat Memory Switch: Testing and Inspection To test the memory selector switch: 1. Remove the memory selector switch. Refer to removal procedure. Memory Selector Switch Continuity 2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Description and Operation > Page 8259 Seat Memory Switch: Service and Repair REMOVAL 1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel. 2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 8268 TIME ALLOWANCE FAILURE CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion NUMBER: 23-044-02 GROUP: Body DATE: Oct. 14, 2002 SUBJECT: NS Strut Tower Corrosion OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion perforation condition at the top of the strut tower/s. MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between the strut and upper load path beam inner panel (inner fender). DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of the following repair procedures. NOTE: ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD BE OBTAINED PRIOR TO BEGINNING REPAIRS. PARTS/MATERIALS REQUIRED EQUIPMENT REQUIRED REPAIR DESCRIPTION: Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or primers and topcoats. Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s. NOTE: REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE PARTS KITS. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion > Page 8274 TIME ALLOWANCE FAILURE CODE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8284 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8285 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8286 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8287 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8293 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8294 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8295 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8296 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Falls Off Mounting Flange NO: 23-34-98 GROUP: Body DATE: Aug. 7, 1998 SUBJECT: Front Door Body Mounted Weatherstrip Retention MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The front door body mounted weatherstrip falls off mounting flange, usually along the top of the door opening. DIAGNOSIS: Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or pulls off easily, perform the Repair Procedure. NOTE: THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP IS REMOVED FOR ANY REASON. PARTS REQUIRED: AR NPN Isopropyl Alcohol REPAIR PROCEDURE: This bulletin involves removing the slip coating on the weatherstrip and mounting flange. 1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the weatherstrip installed. 2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the seal mounts to. 3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as possible without bending it open. If done properly, there will be some black residue on the rag from the weatherstrip. 4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure. 5. Reinstall the weatherstrip on the flange, make sure it is fully seated. 6. Repeat steps 1 through 5 for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-09-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange Weatherstrip: Customer Interest Door Weatherstrip - Falls Off Mounting Flange NO: 23-34-98 GROUP: Body DATE: Aug. 7, 1998 SUBJECT: Front Door Body Mounted Weatherstrip Retention MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: The front door body mounted weatherstrip falls off mounting flange, usually along the top of the door opening. DIAGNOSIS: Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or pulls off easily, perform the Repair Procedure. NOTE: THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP IS REMOVED FOR ANY REASON. PARTS REQUIRED: AR NPN Isopropyl Alcohol REPAIR PROCEDURE: This bulletin involves removing the slip coating on the weatherstrip and mounting flange. 1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the weatherstrip installed. 2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the seal mounts to. 3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as possible without bending it open. If done properly, there will be some black residue on the rag from the weatherstrip. 4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure. 5. Reinstall the weatherstrip on the flange, make sure it is fully seated. 6. Repeat steps 1 through 5 for the other side. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-51-09-92 0.3 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 8314 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5. See Stop lamp switch adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 8315 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Speed Control Switches Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8319 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8323 Vehicle Speed Control Servo - 4 Way Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8324 Cruise Control Servo: Description and Operation SYSTEM OPERATION The servo unit consists of a solenoid valve body, and a vacuum chamber. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8325 Cruise Control Servo: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove air cleaner resonator. Fig. 11 Speed Control Cable End 3. Disconnect the throttle and speed control cable ends from throttle body. Speed Control Cable Case And Vacuum Line - Typical 4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Disconnect vacuum line from nipple on air intake plenum. 6. Remove tie wrap holding vacuum line, throttle cable, and speed control cable together. Speed Control Servo Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8326 7. Remove bolt holding speed control servo to side of battery tray/vacuum reservoir. 8. Remove speed control servo from battery tray. 9. Disconnect wire connector from speed control servo. 10. Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum reservoir. 11. Remove speed control servo. INSTALLATION - Transfer speed control cable to replacement speed control servo. Reverse the preceding operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation SYSTEM OPERATION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 8330 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Remove air cleaner resonator. Fig. 11 Speed Control Cable End 3. Disconnect throttle and speed control cable ends from throttle body. Speed Control Cable 4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Remove tie wrap holding vacuum line, throttle cable, and speed control cable together. 6. Remove nuts holding speed control cable case to servo. 7. Remove cable case from servo. 8. Remove hairpin clip holding cable end to servo diaphragm. 9. Remove speed control cable. INSTALLATION - Reverse the preceding operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8334 Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for any of the following conditions: An indication of Park or Neutral - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction between the road surface and tires is extremely low) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached, then release the switch. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8335 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION - Reverse the preceding operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades Cruise Control Vacuum Reservoir: Customer Interest Speed Control - Does Not Maintain Speed on Grades NUMBER: 08-27-99 GROUP: Electrical EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because of speed control vacuum loss while on up hill grade. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE. SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under low manifold vacuum conditions. The valve may become contaminated and cause it not to seal intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade. DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of vacuum leak is found, perform the Repair Procedure. PARTS REQUIRED: 1 04716740AB Tray, Battery/Vacuum Reservoir EQUIPMENT REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades > Page 8344 Hand Vacuum Pump REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the nut and two bolts from the battery tray, Figure 1. 2. Remove the speed control servo attaching bolt from the battery tray. 3. Disconnect the vacuum lines from the battery tray vacuum reservoir. 4. Remove the battery tray from the vehicle and discard. 5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB. 6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.). 7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.). 8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.) 9. Connect the positive and negative battery terminals. 10. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-08-05-90 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades Cruise Control Vacuum Reservoir: All Technical Service Bulletins Speed Control - Does Not Maintain Speed on Grades NUMBER: 08-27-99 GROUP: Electrical EFFECTIVE DATE: Aug. 27, 1999 SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because of speed control vacuum loss while on up hill grade. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE. SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under low manifold vacuum conditions. The valve may become contaminated and cause it not to seal intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade. DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of vacuum leak is found, perform the Repair Procedure. PARTS REQUIRED: 1 04716740AB Tray, Battery/Vacuum Reservoir EQUIPMENT REQUIRED: Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does Not Maintain Speed on Grades > Page 8350 Hand Vacuum Pump REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Remove the nut and two bolts from the battery tray, Figure 1. 2. Remove the speed control servo attaching bolt from the battery tray. 3. Disconnect the vacuum lines from the battery tray vacuum reservoir. 4. Remove the battery tray from the vehicle and discard. 5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB. 6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.). 7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.). 8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.) 9. Connect the positive and negative battery terminals. 10. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-08-05-90 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Page 8351 Cruise Control Vacuum Reservoir: Description and Operation SYSTEM OPERATION The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Page 8352 Cruise Control Vacuum Reservoir: Testing and Inspection 1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch. Fig. 4 Servo Harness Connector 2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply 10 - 15 inches of vacuum. 6. If servo pulls cable, replace servo. 7. Ground Pin 1 on servo. 8. Check that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one minute, check if cable is still holding. If cable does not hold replace the servo. 9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo. 10. Connect 4 way electrical connector and vacuum harness to servo. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Page 8353 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Remove battery. 3. Remove battery tray. 4. Disconnect vacuum hoses from vacuum reservoir INSTALLATION 1. Connect vacuum hoses to vacuum reservoir. 2. Install battery tray 3. Install battery. 4. Connect negative cable to battery. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation Brake Switch (Cruise Control): Description and Operation SYSTEM OPERATION Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 8358 Brake Switch (Cruise Control): Testing and Inspection Fig. 21 Stop Lamp Switch 1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector from stop lamp switch. Using an ohmmeter, switch continuity may be checked as follows: 2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch plunger depressed, there should be continuity: - Between Pin 1 and Pin 2. - Between Pin 3 and Pin 4. 4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5. See Stop lamp switch adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Page 8359 Brake Switch (Cruise Control): Service and Repair REMOVAL Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from bracket. Disconnect wiring harness connector. INSTALLATION Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure. Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch with the plunger facing forward in car. There is an index key on the switch that mates with the bracket slot at the top of the square hole. Align key and push switch into square hole in bracket while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is released. Pull back on the pedal to assure correct adjustment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Speed Control Switches Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 8363 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8367 Cruise Control Switch: Description and Operation SYSTEM OPERATION There are two separate switch pods that operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual for more information on speed control switch functions and setting procedures. When speed control is selected by depressing the ON switch, the PCM allows a set speed to be stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored in the PCM. For added safety,the speed control system is programmed to disengaged for any of the following conditions: An indication of Park or Neutral - An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged) - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction between the road surface and tires is extremely low) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch when speed is greater than 25 mph restores the vehicle to the target speed that was stored in the PCM. NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. While the speed control is engaged, the driver can increase the vehicle speed by depressing the ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached, then release the switch. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8368 Cruise Control Switch: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and speed control switches. Speed Control Switches 5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control switch from airbag/horn pad. INSTALLATION - Reverse the preceding operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8377 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8383 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8392 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control Number: 21-06-99 Group: Transmission Date: April 2, 1999 SUBJECT: Intermittent Loss of Speed Control OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors. MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (International Market) 1995 - 1999 (FJ) Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (International Market) 1995 - 1999 (JA) Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1997 (PR) Prowler NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR. SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors should be checked for spread terminals. DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly different between the old and new sensors. When a new sensor is installed on an early vehicle the connector terminals may be spread from the original sensor and may cause an intermittent speed control condition. Anytime a new sensor is installed on an early vehicle the connector must also be replaced. PARTS REQUIRED: 1 05014469AA Wiring Repair Package, Input Speed Sensor 1 05014471AA Wiring Repair Package, Output Speed Sensor REPAIR PROCEDURE: 1. Disconnect and isolate negative battery cable. 2. Raise vehicle on a suitable hoist. 3. Locate and disconnect the input and/or output sensor connectors. 4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor fastener (Christmas tree type fastener). 5. Remove the end tape from the input/output harness and push back the convolute tubing. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8398 6. Cut the harness just above the top of the connector to remove the input and/or output connector. 7. Remove approximately 1/2 inch of insulation from the end of the two wires. 8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of insulation has been removed from the repair harness wires. 9. Place a heat shrink tube over each of the two wires on the repair harness. 10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness and repair harness wires. Repeat procedure for the second wire. 11. Solder the connection together using rosin core type solder. 12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 13. Cover wires with attached convolute and add additional convolute from the repair package. 14. Tape ends with black electrical tape. 15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust. 16. If required connect O2 sensor fastener and attach upper harness clip. 17. Connect input/output sensor connectors. 18. Connect negative battery cable. 19. Verify transmission systems are functioning as designed. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs. FAILURE CODE: XX - Service Adjustment Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on the right side of the message center located at the top of the instrument panel. The purpose of the warning lamp is discussed in detail below. The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition which results in a shutdown of ABS function or when the body controller does not receive C2D messages from the CAB. When the ignition key is turned to the on position, the ABS Warning Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on, only the ABS function of the brake system is affected. The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on. The ABS warning lamp is controlled by the CAB and the body controller through a diode located in the wiring harness junction block. The junction block is located under the instrument panel to the left of the steering column. The CAB and the body controller, controls the yellow ABS warning lamp by directly grounding the circuit. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Conditioning Indicator Lamp > Component Information > Service and Repair Air Conditioning Indicator Lamp: Service and Repair REMOVAL 1. Remove rear heater-A/C control from trim panel. 2. On the back of control opposite from the wire connectors, locate the bulb socket lug. 3. Rotate the socket counterclockwise and pull the socket from the control. INSTALLATION - For installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8410 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8411 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8412 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8413 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8414 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8415 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8416 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8417 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8418 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8419 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8420 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Audible Warning Device: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test Revisions NUMBER: 26-12-97I GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013 DESCRIPTION OF CHANGES Revisions to the ABS warning lamp test Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8433 94 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8434 95 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8435 Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS Revisions NUMBER: 26-12-97F GROUP: Miscellaneous DATE: December, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012 DESCRIPTION OF CHANGES Revisions to the ABS warning light procedure Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8436 244 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8437 245 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Technical Service Bulletins > Page 8438 Brake Warning Indicator: Description and Operation The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank position. The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb is then illuminated by completing the ground circuit either through the park brake switch, the fluid level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank position. The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly. The purpose of the sensor is to provide the driver with an early warning that brake fluid level in the master cylinder fluid reservoir has dropped to below normal. This may indicate: (1) Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. (2) Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level sensor closes to ground the brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions Compass: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8451 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8452 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8453 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8454 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 Compass: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 8468 Compass: Description and Operation SYSTEM OPERATION Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC consists of an electronic module that displays compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC to change mode of operation when the ignition is ON. Examples: Compass/Temperature - Trip odometer (ODO) - Average miles per gallon (ECO) - Instant miles per gallon (ECO) - Distance to empty (DTE) - Elapsed time (ET) - Off The CMTC module in the overhead console has three buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. Compass The CMTC is self calibrating and usually requires no adjustment. The compass will continuously perform a slow calibration to compensate for small magnetic variations common to any automobile. Uncommon magnetic shifts may be caused by items such as magnetic base antennas, which can permanently alter the magnetic field of the vehicle roof panel. If excessive magnetic field continues for 5 minutes, the compass heading will go blank and only the CAL symbol will illuminate. When this occurs, the vehicle roof panel may require demagnetizing. Refer to the demagnetizing procedure. Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only one or two of the eight possible headings. Although the compass will eventually compensate for this shift, it could take several ignition cycles. The compensation process can be expedited by manually activating the fast calibration routine. Refer to the fast calibrating procedure. This procedure may be performed anytime that the compass appears to be inaccurate. If the calibration data stored in the body control module is not received, the compass will read only NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone through three complete circles without stopping, in an area free of magnetic disturbance. If module displays temperature while the compass is blank, turn off ignition and run self diagnostics then demagnetize the vehicle. After demagnetizing, check compass calibration number, refer to Self Diagnostic Test. If greater than 15, demagnetize again until reading is less than 15. If compass still goes blank after demagnetizing then check internal diagnostics and demagnetize. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Component Tests and General Diagnostics Compass: Component Tests and General Diagnostics Self-Check For Compass Mini-Trip (CMTC) The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on many of its internal functions. CMTC diagnostics may be performed using a scan tool and the proper Body Control Module Testing and Inspection Procedures or by using the following procedure. 1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn ignition switch to the ON position. The CMTC will perform internal checks while lighting all segments of the vacuum florescent display. Upon completion of the internal check the CMTC will display. PASS - FAIL - CCD If any segment of the CMTC fails to light replace the module. If FAIL is displayed replace the module. If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper operation. If the CCD bus and the BCM are OK, replace the CMTC module. Additional diagnostic trouble code information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Diagnostic Charts Diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Page 8471 Compass: Adjustments Setting the Compass The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the vehicle has gone in three complete circles without stopping, in an area free of magnetic disturbance. If the module displays the temperature while the compass is blank or shows a false reading, the vehicle must be demagnetized. If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module must be replaced. Setting the Variance Variance is the difference between magnetic north and geographic north. To determine the variance for the area you are in, refer to the zone map above. The number shown for your area is the variance number for your area. 1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the CMTC will set the variance to 8 and enter the fast calibration mode. 3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP button to set the zone number. 5. Press the US/M button and resume normal operation. NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can cause the compass to give false readings. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Page 8472 Compass: Service and Repair Variance Settings COMPASS CALIBRATION PROCEDURE Variance is the difference between magnetic North and geographic North. To adjust the compass variance set the CMTC to Compass/Temperature mode and press RESET buttons for 5 seconds. The symbol VAR and the current variance zone number will be displayed. Press the STEP button to select the proper variance zone. Press the US/Metric button to save the new variance zone and normal CMTC operation. If both buttons are held for 10 seconds instead 5 seconds the CMTC will set variance to 8 and enter the fast calibration mode. COMPASS CALIBRATION PROCEDURE (FAST METHOD) When the compass is subjected to excessive magnetic fields, the CMTC automatically enters a fast calibration mode where is tries to compensate for the large magnetic shifts. If the compass is inaccurate, appears to be inaccurate and the CAL is not illuminated the fast calibration mode may be manually entered by using the following procedure. 1. Set the CMTC to Compass/Temperature mode and press the reset button for 10 continuous seconds. Manual activation of the fast calibration is generally not required. 2. Compass variance sets to the default of 8 after the fast calibration is manually activated. 3. Complete the compass variance setting procedure by referring to the Compass Variance Procedure. 4. Drive the vehicle in three 3600 turns in an area free from large metal objects. If the CAL symbol remains lit after completing this step, the roof panel may need demagnetizing. DEMAGNETIZING PROCEDURE A magnetic field can adversely affect the compass. Magnetic interference can magnetize the roof panel. Magnetizing can be caused by placing a permanent magnet in contact with the roof panel. Example: Magnetic Base Antenna - Magnetic screwdriver - Audio speakers - Refrigerator magnets - Pizza Signs - Bubble gum flasher lights Removing magnetic interfering objects will usually restore normal compass operation. If the compass display remains blank while the CAL label is illuminated, then the roof panel requires demagnetizing. To demagnetize use Special Tool 6029 for demagnetizing the roof panel. The demagnetizing procedure will demagnetize the roof and mounting screws in the overhead console. It is important that you follow the instructions below exactly. The mounting screws and the mounting brackets around the compass area are steel, and therefore aid in the demagnetizing of the roof panel. 1. Be sure the ignition switch is in the OFF position before you begin the demagnetize procedure. 2. Plug the demagnetizing tool into a standard 110/115 volt AC outlet, keeping the demagnetizing tool at least 12 inches away from the compass area Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Page 8473 when plugging it in. 3. Slowly approach and contact the console mounting screw with the plastic coated tip of the tool for at least two seconds. 4. With the demagnetizing tool still energized, slowly back it away from the screw until the tip is at least 12 inches from the screw head. 5. Repeat the last step with all the console mounting screws. 6. After you have pulled at least 12 inches from the last screw, remove the demagnetizing tool from inside vehicle and disconnect it from the electrical outlet. 7. Place an 8 1/2 X 11 inch piece of paper length-wise on the roof of vehicle directly above compass. The purpose of the paper is to protect the roof panel from scratches and define the area to be demagnetized. 8. Plug in the demagnetizing tool, keeping it at least two feet away from the compass unit. 9. Slowly approach the center of the roof panel at the windshield with the demagnetizing tool plugged in. 10. Contact the roof panel with the tip of the tool. Using slow sweeping motions of 1/2 inch between sweeps. Move the tool approximately four inches either side of the center line and at least 11 inches back from the windshield. 11. With the demagnetizing tool still energized, slowly back away from the roof panel until the tip is at least two feet from the roof before unplugging the tool. 12. Recalibrate compass, refer to the compass calibration procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8480 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8490 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8491 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Driver/Vehicle Information Display: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 Driver/Vehicle Information Display: Electrical Diagrams Information Center Wiring Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 Message Center (Part 1 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 Message Center (Part 2 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 Message Center (Part 3 Of 4) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 Message Center (Part 4 Of 4) NOTE: To view sheets referred in these diagrams, see Diagram Information and Instructions/Complete Body and Chassis Diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center Driver/Vehicle Information Display: Service and Repair Message Center REMOVAL 1. Remove A-pillar trim. 2. Remove instrument panel top cover. Refer to instrument panel top cover removal procedures. 3. Disconnect the wire connector from back of message center. 4. Remove screws holding message center to instrument panel top cover. 5. Remove message center from instrument panel top cover. INSTALLATION 1. Place message center in position on top cover. 2. Install screws to hold message center to instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install instrument panel top cover. 5. Install A-pillar trim. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Message Center > Page 8511 Driver/Vehicle Information Display: Service and Repair Message Center Lamp REMOVAL 1. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Removal procedures. Message Center Lamp Location 2. Locate the lamp in question. 3. Remove lamp and check lamp. If lamp is good test the power supply to the lamp. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > About Diagnostic Procedures Fuel Gauge: Testing and Inspection About Diagnostic Procedures These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8516 Fuel Gauge: Testing and Inspection Diagnostic Chart Fuel Gauge Diagnosis (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8517 Fuel Gauge Diagnosis (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8518 Fuel Gauge Diagnosis (Part 3 Of 3) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 8522 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNINGS: - Before beginning any service procedures that involves removing the air bag. Remove and isolate the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable the air bag system. Failure to do this could result in accidental air bag deployment and possible personal injury. - The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to diagnose, remove or install the air bag system components you must first disconnect and isolate the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag components, have special coatings and are specifically designed for the air bag system. they must never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct fasteners provided in the service package or fasteners listed in the parts books. Before servicing a steering column equipped with an air bag, use proper and safe service procedures . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming Air Bag Disarming WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System component service procedures. This will disable the airbag system. Failure to disconnect the battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components . Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8529 Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming Air Bag Arming 1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will not erase. Refer to Air Bags to diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is a system malfunction. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Service and Repair Instrument Panel Circuit Board: Service and Repair Instrument Cluster Printed Circuit Board REMOVAL 1. Remove the instrument cluster. 2. Remove the instrument cluster back panel. 3. Disconnect the electronic cluster wire connector from the printed circuit board. 4. Remove the screws holding wire connector insulator to the instrument cluster shell and the printed circuit board. 5. Remove the screws holding printed circuit board to the cluster shell. 6. Remove the printed circuit board from the cluster. INSTALLATION - For Installation, reverse the above procedures. After installing the print circuit board it will have to be calibrated using a scan tool (DRB III). NOTE: Speedometer and/or Tachometer will not operate properly until all gauges have been calibrated. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation This vehicle does not have a Maintenance Reminder Light option. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures Odometer: Testing and Inspection About Diagnostic Procedures These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8540 Odometer: Testing and Inspection Odometer Diagnosis Odometer Diagnosis (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8541 Odometer Diagnosis (Part 2 Of 2) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Testing and Inspection > Page 8542 Odometer: Service and Repair REMOVAL 1. Remove instrument cluster. 2. Remove cluster lens. 3. Disconnect wire connector from odometer and transmission range indicator. 4. Remove screws holding odometer and transmission range indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster. INSTALLATION 1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install instrument cluster. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Engine Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations > Page 8550 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Cigarette Lighter Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 8559 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations > Page 8563 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures Speedometer Head: Testing and Inspection About Diagnostic Procedures These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8568 Speedometer Head: Testing and Inspection Speedometer Diagnosis Speedometer Diagnosis (Part 1 Of 5) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8569 Speedometer Diagnosis (Part 2 Of 5) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8570 Speedometer Diagnosis (Part 3 Of 5) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8571 Speedometer Diagnosis (Part 4 Of 5) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8572 Speedometer Diagnosis (Part 5 Of 5) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures Tachometer: Testing and Inspection About Diagnostic Procedures These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8577 Tachometer: Testing and Inspection Tachometer Test Tachometer Diagnosis (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8578 Tachometer Diagnosis (Part 2 Of 2) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Temperature Gauge: Initial Inspection and Diagnostic Overview These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8584 Temperature Gauge: Component Tests and General Diagnostics Temperature Diagnosis (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8585 Temperature Diagnosis (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8586 Temperature Diagnosis (Part 3 Of 3) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Gauge Sending Unit ........................................................................................................................................................... 7 Nm (60 inch lbs.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Testing and Inspection Traction Control Indicator Lamp: Testing and Inspection The traction control light is tested by cycling the traction control switch on and off. The traction control switch used on this vehicle is a momentary contact type switch. The test procedure for the traction control light is performed as follows: Press the traction control switch once and the "Trac Off" lamp will illuminate. With the "Trac Off" lamp illuminated, press the traction control switch again and the "Trac Off" lamp will turn off. If the traction control lamp does not function as described in the test above, diagnosis of the traction control switch, lamp, wiring and other related components of the traction control system is required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures Transmission Shift Position Indicator Lamp: Testing and Inspection About Diagnostic Procedures These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing and Inspection The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The following CCD bus messages are continuously monitored by the diagnostic system: - Body Control Module - Powertrain Control Module - Transmission Control Module, if equipped NOTE: Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8597 Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Gear Indicator Display Diagnostic Chart Electronic Gear Indicator Display Diagnosis (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8598 Electronic Gear Indicator Display Diagnosis (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8599 Electronic Gear Indicator Display Diagnosis (Part 3 Of 3) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8600 Transmission Shift Position Indicator Lamp: Testing and Inspection Mechanical Transmission Range Indicator (PRND21) Diagnosis Mechanical Transmission Range Indicator (PRND21) (Part 1 Of 2) Mechanical Transmission Range Indicator (PRND21) (Part 2 Of 2) Additional diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration Under Testing and Inspection at the system level. See: Testing and Inspection Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service and Repair > Electronic Odometer and Transmission Range Indicator Transmission Shift Position Indicator Lamp: Service and Repair Electronic Odometer and Transmission Range Indicator REMOVAL 1. Remove instrument cluster. 2. Remove cluster lens. 3. Disconnect wire connector from odometer and transmission range indicator. 4. Remove screws holding odometer and transmission range indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster. INSTALLATION 1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install instrument cluster. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Service and Repair > Electronic Odometer and Transmission Range Indicator > Page 8603 Transmission Shift Position Indicator Lamp: Service and Repair Mechanical Transmission Range Indicator REMOVAL 1. Remove instrument cluster. 2. Remove cluster lens. 3. Remove screws holding mechanical transmission range indicator to back of cluster lens. 4. Remove mechanical transmission range indicator from cluster lens. INSTALLATION 1. Position transmission range indicator on cluster lens. 2. Install mechanical range indicator and attaching screws to back of cluster lens. 3. Install cluster lens. 4. Install instrument cluster. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair Brake Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8616 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8617 Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8618 Brake Light Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8619 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8620 Brake Light Switch: Service and Repair REMOVAL Stop Lamp Switch 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALLATION NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Disengage clips holding CHMSL access cover to liftgate. 3. Separate cover from liftgate. 4. Rotate bulb socket counterclockwise one quarter turn. CHMSL Bulb 5. Pull socket from lamp. 6. Pull bulb from socket. INSTALLATION 1. Insert bulb into socket. 2. Insert socket into lamp. 3. Rotate bulb socket clockwise one quarter turn. 4. Place CHMSL access cover in position on liftgate. 5. Engage clips to hold access cover to liftgate. 6. Verify CHMSL operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb Courtesy Lamp Bulb: Service and Repair Front Door Courtesy Lamp Bulb REMOVAL Door Courtesy Lamp Lens 1. Using a small, flat bladed pry tool, pry rear edge of courtesy lamp lens from courtesy lamp. 2. Separate lens from lamp. 3. Squeeze brass lamp bulb contacts together gently Door Courtesy Lamp Bulb 4. Disengage bulb wire contacts from lamp bulb contacts. 5. Separate bulb from lamp. INSTALLATION 1. Position bulb to lamp. 2. Engage bulb wire contacts to lamp bulb contacts. 3. Insert long edge of lens into lamp housing. 4. Press on center of lens to engage remainder of clips Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 8630 Courtesy Lamp Bulb: Service and Repair Header Reading / Courtesy Lamp Bulb Reading/Courtesy Lamp Lens REMOVAL 1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and lamp housing. 2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between lamp light shield and lamp housing at inboard rear corner of light shield. Reading/Courtesy Lamp Light Shield 4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite contact and rotate. 6. Separate bulb from lamp bulb contacts. INSTALLATION 1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position. 2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6. Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both pivots are seated. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 8631 Courtesy Lamp Bulb: Service and Repair Liftgate Courtesy Lamp Bulb REMOVAL 1. Remove liftgate courtesy lamp. 2. Insert a small, flat bladed pry tool between courtesy lamp lens and courtesy lamp body. Liftgate Courtesy Lamp Bulb 3. Carefully depress tabs holding lens to courtesy lamp body. 4. Separate lamp lens from lamp body 5. Carefully press lamp bulb contact toward opposite contact. 6. Separate bulb from lamp body. INSTALLATION 1. Carefully press lamp bulb contact toward opposite contact. 2. Position bulb to lamp bulb contacts. 3. Position long side of lamp lens to tabs on lamp body. 4. Press on center of lens to engage tabs on opposite side of lamp body. 5. Install liftgate courtesy lamp. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 8632 Courtesy Lamp Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb REMOVAL 1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading lamp bulb socket one quarter turn counter clockwise. Reading/Courtesy Lamp 3. Pull socket out of lamp. 4. Pull bulb from socket. INSTALLATION 1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens onto lamp lens pivots. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Front Door Courtesy Lamp Bulb > Page 8633 Courtesy Lamp Bulb: Service and Repair Rail Lamp Module Bulb REMOVAL Rail Lamp Module Lens 1. Using a small screw driver, pry stationary end of rail lamp lens from rail lamp module. 2. Separate lens tab from between rail lamp module and rail lamp switch. 3. Separate lens from lamp. Rail Lamp Module Bulb 4. Pull bulb from lamp . INSTALLATION 1. Push bulb into bulb contacts in rail lamp module. 2. Insert tab on lamp lens between rail lamp module and rail lamp switch. 3. Snap lens onto lens pivots on module. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service and Repair Glove Box Lamp: Service and Repair REMOVAL 1. Remove glove box lamp/switch from instrument panel. Glove Box Lamp 2. Pull bulb from glove box lamp. INSTALLATION 1. Push bulb into glove box lamp. 2. Install glove box lamp/switch in instrument panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations > Page 8643 Interior Light Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations > Page 8644 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Locations Daytime Running Lamp: Locations Combination Flasher Location The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions (for Canadian vehicles), and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions three and four, where all wiring associated with its operation is terminated. The junction block is adjacent to and left of the steering column of the vehicle. On vehicles built for use in the United States, only position four is used. Vehicles built for use in Canada utilize both positions three and four. To gain access to the device, remove the lower steering column cover and knee blocker. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Locations > Page 8648 Daytime Running Lamp: Description and Operation SYSTEM OPERATION Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions (for Canadian vehicles), and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions three and four, where all wiring associated with its operation is terminated. The junction block is adjacent to and left of the steering column of the vehicle. On vehicles built for use in the United States, only position four is used. Vehicles built for use in Canada utilize both positions three and four. To gain access to the device, remove the lower steering column cover and knee blocker. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair REMOVAL 1. Insert a small, flat bladed pry tool between dome lamp lens and dome lamp body on left side of dome lamp. Dome Lamp Bulb 2. Disengage left side of dome lamp lens from lamp body. 3. Pull bulb from lamp socket INSTALLATION 1. Push bulb into lamp socket. 2. Pivot dome lamp lens upward. Verify that lamp lens hook is above the headlining. 3. Engage left side of dome lamp lens to lamp body Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair REMOVAL 1. Remove fog lamp from vehicle. 2. Remove rear cover from fog lamp. Fog Lamp Bulb 3. Disengage wire clip holding bulb in fog lamp. 4. Hinge wire retainer clip out of bulb removal path. 5. Pull bulb from lamp. 6. Disengage wire connector from fog lamp wire harness. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other oily surfaces, reduced bulb life will result. 1. Engage wire connector into fog lamp wire harness. 2. Insert bulb into lamp so index notches on bulb engage with bosses in lamp. 3. Hinge wire retainer clip over bulb base. 4. Engage wire clip to hold bulb into lamp. 5. Install rear cover on fog lamp. 6. Install fog lamp on vehicle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Instrument Panel Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8660 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 Fog/Driving Lamp Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 Fog/Driving Lamp Relay: Electrical Diagrams Front Lighting (Part 2 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 Front Lighting (Part 3 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 Front Lighting (Part 6 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation Hazard Warning Flasher: Description and Operation SYSTEM OPERATION Combination Flasher Without Daytime Running Lamp Module Combination Flasher Location The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit must be completed to the module. While the combination flasher is idle, there is no current drawn through the module. The device does not become active until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of 300 mA and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 mA through the multi-function switch. With Daytime Running Lamp Module Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Description and Operation > Page 8688 Junction Block Terminal Pins The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA, and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL Hazard Warning Flasher: Testing and Inspection Combination Flasher Diagnosis With DRL Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8691 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8692 Combination Flasher Diagnosis With DRL (Part 3 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8693 Hazard Warning Flasher: Testing and Inspection Combination Flasher Diagnosis Without DRL Combination Flasher Diagnosis Without DRL (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8694 Combination Flasher Diagnosis Without DRL (Part 2 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8695 Hazard Warning Flasher: Testing and Inspection With Daytime Running Lamps Module Electronic Combination Flasher With DRL Circuit Junction Block Terminal Call-Out With DRL The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8696 This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8697 Hazard Warning Flasher: Testing and Inspection Without Daytime Running Lamps Module Electronic Combination Flasher Circuit Junction Block Terminal Call-Out The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8698 - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Testing and Inspection > Page 8699 Hazard Warning Flasher: Service and Repair With/Without DRL Module REMOVAL 1. Remove lower steering column cover. 2. Remove knee blocker. 3. Pull combination flasher from junction block. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair Headlamp Bulb REMOVAL 1. Release hood latch and open hood. 2. From behind radiator closure panel, disengage wire connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring counter clockwise. 4. Disengage retaining ring from headlamp. 5. Pull headlamp bulb from back of headlamp. INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. 1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Engage wire connector into headlamp bulb base. 5. Verify headlamp alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Description and Operation Headlamp Control Module: Description and Operation GENERAL INFORMATION Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to humid conditions. This is considered normal. The fogging will dissipate with increased ambient temperature or headlamp usage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Description and Operation > Page 8710 Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure panel. Headlamp Module 4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from back of headlamp module. 6. Separate headlamp module from vehicle. INSTALLATION 1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel. 6. Verify headlamp operation and alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation GENERAL INFORMATION The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 8720 Headlamp Switch: Testing and Inspection Headlamp Switch Test Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch Headlamp Switch REMOVAL 1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 8723 Headlamp Switch: Service and Repair Headlight Switch Lamp Headlamp Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5. Pull bulb socket from headlamp switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8728 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK. Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is OK, on one side of fuse, the fuse is blown, proceed to Step 3. 3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If amperage draw is greater than 20 amps without the horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded circuit exists between the horn relay and the horn. Proceed to step Step 5. 4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn switch or circuit is shorted. If the amperage draw does not drop to 0 amps, repair short at the Junction Block. 5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn sounds, replace the faulty horn. If amperage does not drop with both horns disconnected and the horn switch depressed, proceed to Step 6. 6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn relay to ground. If continuity is detected, the circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness. Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress horn switch and test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4. 3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay in the Junction Block. a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4. 4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors with horn switch depressed. a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO continuity, replace airbag cover. 6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8729 Horn And Connector 8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals of the wire harness. a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9. 9. With the horn switch depressed, test for voltage between the X2 circuit and ground. a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit between the relay and the horns. Horns Sound Continuously CAUTION: Continuous sounding of horns may cause relay to fail. The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1. Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay. 3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install horn relay into junction block. a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3 circuit from junction block to clockspring in steering in steering column. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Page 8736 Key Cylinder Lamp: Service and Repair Ignition Halo Lamp Bulb REMOVAL 1. Remove steering column trim covers. Ignition Halo Lamp Bulb 2. Rotate bulb socket counter clockwise one quarter turn. 3. Pull bulb socket from halo lamp. INSTALLATION 1. Push bulb socket into halo lamp. 2. Rotate bulb socket clockwise one quarter turn. 3. Install steering column trim covers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair REMOVAL 1. Remove screws attaching license plate lamp lens to liftgate. 2. Remove license plate lamp lens from lamp. 3. Rotate lamp socket counterclockwise one quarter turn. License Plate Lamp Bulb 4. Pull socket from lens. 5. Pull bulb from socket. INSTALLATION 1. Install bulb into socket. 2. Insert socket into lens. 3. Rotate lamp socket clockwise one quarter turn. 4. Place license plate lamp lens in position in lamp. 5. Install screws attaching license plate lamp lens. 6. Verify license plate lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection Marker Lamp: Testing and Inspection The dome lamps operate in conjunction with the Remote Keyless Entry system. For additional diagnostic information on lamp operation controlled by Body Control Module (BCM), refer to the Powertrain Management/Computer and Control Systems/Body Control Module (BCM). Reading/dome Lamp Diagnosis Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. From under front wheelhouse, remove access cover behind park and turn signal lamp. 2. Through access hole in wheelhouse, rotate park and turn signal socket counterclockwise one quarter turn. Park And Turn Signal Lamp Bulb 3. Pull socket from back of lamp. 4. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Through access hole in wheelhouse, insert socket into back of lamp. 3. Rotate park and turn signal socket clockwise one quarter turn. 4. Install access cover and verify lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Instrument Panel Connections Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8755 Junction Block Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp Relay: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 Fog/Driving Lamp Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8776 Fog/Driving Lamp Relay: Electrical Diagrams Front Lighting (Part 2 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8777 Front Lighting (Part 3 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8778 Front Lighting (Part 6 Of 8) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Description and Operation Headlamp Control Module: Description and Operation GENERAL INFORMATION Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to humid conditions. This is considered normal. The fogging will dissipate with increased ambient temperature or headlamp usage. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Description and Operation > Page 8782 Headlamp Control Module: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure panel. Headlamp Module 4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from back of headlamp module. 6. Separate headlamp module from vehicle. INSTALLATION 1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel. 6. Verify headlamp operation and alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8789 Horn Relay: Testing and Inspection 1. Remove horn relay. Horn Relay 2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance. If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn relay. a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as necessary. 4. Using voltmeter, test voltage at: a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM. c. If incorrect voltage repair as necessary. 5. Insert a jumper wire between terminal 30 and 87 of the power distribution center. a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn Test. Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK. Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is OK, on one side of fuse, the fuse is blown, proceed to Step 3. 3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If amperage draw is greater than 20 amps without the horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded circuit exists between the horn relay and the horn. Proceed to step Step 5. 4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn switch or circuit is shorted. If the amperage draw does not drop to 0 amps, repair short at the Junction Block. 5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn sounds, replace the faulty horn. If amperage does not drop with both horns disconnected and the horn switch depressed, proceed to Step 6. 6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn relay to ground. If continuity is detected, the circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness. Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress horn switch and test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4. 3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay in the Junction Block. a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4. 4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors with horn switch depressed. a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO continuity, replace airbag cover. 6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8790 Horn And Connector 8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals of the wire harness. a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9. 9. With the horn switch depressed, test for voltage between the X2 circuit and ground. a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit between the relay and the horns. Horns Sound Continuously CAUTION: Continuous sounding of horns may cause relay to fail. The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1. Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the X3 cavity of the horn relay to ground. a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay. 3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install horn relay into junction block. a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3 circuit from junction block to clockspring in steering in steering column. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8798 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8799 Brake Light Switch: Service Precautions CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8800 Brake Light Switch: Description and Operation The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped with speed control, the stop lamp switch will deactivate speed control when the brake pedal is depressed. The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps. The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8801 Brake Light Switch: Adjustments 1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then while keeping the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in the square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the bracket. Stop Light Switch Location In Vehicle CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can result. 5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8802 Brake Light Switch: Service and Repair REMOVAL Stop Lamp Switch 1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3. Disconnect wiring harness connector from stop lamp switch. INSTALLATION NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using procedure in Step 1. 1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position. 2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch into the bracket using the following procedure. Depress the brake pedal as far down as possible. Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into bracket. CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result. 4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the correct position. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8811 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8812 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8813 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8814 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8815 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8816 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8822 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8823 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8824 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8825 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8826 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8827 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL 1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument panel. Glove Box Lamp And Switch 3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair Hazard Warning Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation GENERAL INFORMATION The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 8840 Headlamp Switch: Testing and Inspection Headlamp Switch Test Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test. Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within specifications replace as necessary. The Chrysler Town and Country is available with optional Automatic Headlamps. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch Headlamp Switch: Service and Repair Headlight Switch Headlamp Switch REMOVAL 1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlight Switch > Page 8843 Headlamp Switch: Service and Repair Headlight Switch Lamp Headlamp Switch Lamp REMOVAL 1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5. Pull bulb socket from headlamp switch. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 8850 Interior Light Switch: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations > Page 8851 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8855 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 8856 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8870 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8871 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8872 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8873 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8874 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8875 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound Technical Service Bulletin # 19-09-99 Date: 000211 Steering Wheel - Click/Rattle Sound NUMBER: 19-09-99 GROUP: Steering EFFECTIVE DATE: Feb. 11, 2000 SUBJECT: Click/Rattle Sound In Area Of Steering Wheel OVERVIEW: This bulletin involves checking steering column components for correct torque, lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction switch and steering wheel. MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager (International Market) SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or input from the road surface. It may be difficult to readily repeat the sound once it has occurred until additional road input is experienced, such as running over an expansion strip. DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair Procedure. PARTS REQUIRED: AR NPN Tape, Foam 3M P/N 06375 or Equivalent AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent AR 05018626AA Grease, Damping POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 19-34-05-93 0.6 Hrs. FAILURE CODE: XX - Service Adjustment Repair Procedure THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Make sure the front wheels of the vehicle are in the straight ahead position. 2. Disconnect and isolate the negative/ground battery cable. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8881 Fig. 1 3. Remove the screws attaching the lower steering column cover and separate the cover from the instrument panel (Figure 1). 4. Disconnect the parking brake release cable from the parking brake release lever. Fig. 2 5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and separate the liner from the instrument panel (Figure 2). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8882 Fig. 3 6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn until the steering wheel lock engages (Figure 3). 7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag module from the steering wheel. Fig. 4 8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches. Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped with steering wheel mounted radio controls disconnect the radio control wiring connector from the clock spring (Figure 4). 9. Remove the steering wheel retaining nut from the steering column shaft. 10. Remove the steering wheel damper from the steering wheel. CAUTION DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN SHAFT WHEN REMOVING THE STEERING WHEEL. WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8883 HALF INCH THE CLOCK SPRING WILL BE DAMAGED. 11. Remove the steering wheel from the steering column shaft using a steering wheel puller. CAUTION THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE SHROUDS. 12. Remove the three screws attaching the upper and lower shrouds to the steering column and separate the shrouds from the column. 13. Disconnect the vehicle wiring harness connectors from the clockspring assembly. CAUTION DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION SWITCH. 14. Remove the clockspring from the multifunction switch. Fig. 5 15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm (50 in. lbs.), (Figure 5). Fig. 6 16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6). Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8884 Fig. 7 17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the clockspring (Figure 7). Fig. 8 18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8). Be sure the tape does not extend past the crosshatched area of the multifunction switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8885 Fig. 9 19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9). 20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle harness connector. 21. Install the lower steering column shroud onto the steering column. Install and securely tighten the screw attaching the lower shroud to the column. 22. Install the upper steering column shroud and securely tighten the two screws attaching the upper to lower shroud. CAUTION DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING NUT. Fig. 10 23. Align the master splines on the steering wheel and the steering column shaft as well as the flats on the steering wheel hub with the formations on the clockspring and install the wheel onto the shaft. Wiring leads from the clock spring must be routed as shown in Figure 10. 24. Install the steering wheel damper as shown in Figure 4. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8886 25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.). 26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag module. 27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm (100 in.lbs.). 28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten the 10 attaching bolts. 29. Install the parking brake release cable to the parking brake release lever in the lower steering column cover. 30. Install the lower steering column cover on the lower instrument panel. Install and securely tighten the attaching screws. 31. Connect the negative battery cable. 32. Set the clock to the correct time. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Combination Flasher Location Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Flasher: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 Turn Signal Flasher: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Turn Signal Flasher: Connector Views Junction Block Terminal Pins Junction Block Terminal Call-Out With DRL Junction Block Terminal Pins Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 Junction Block Terminal Call-Out Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 Turn Signal Flasher: Electrical Diagrams Electronic Combination Flasher With DRL Circuit Junction Block Terminal Call-Out With DRL Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Electronic Combination Flasher Circuit Junction Block Terminal Call-Out Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) Turn Signal Flasher: Description and Operation Combination Flasher -- With Daytime Running Lamps (DRL) Combination Flasher Location SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. FLASHER MODULE DESCRIPTION The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4, where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the flasher, remove the lower steering column cover and knee blocker. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8916 Junction Block Terminal Pins FLASHER MODULE OPERATION The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime running light functions, and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher/DRL may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL mode, the ignition circuit must be completed to the module. While the combination flasher portion is idle, there is no current drawn through the module. The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition OFF, there is no current drawn through the module. While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the DRL function. The DRL function may be inhibited by applying a signal ground input from either the park brake circuit or the headlamp relay activation circuit. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of 300 mA, and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground that could draw a maximum of 600 mA. through the multi-function switch. Electronic Combination Flasher With DRL Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8917 Junction Block Terminal Call-Out With DRL CIRCUIT OPERATION The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8918 Turn Signal Flasher: Description and Operation Combination Flasher -- Without Daytime Running Lamps (DRL) Combination Flasher Location SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. FLASHER MODULE DESCRIPTION The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4, where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the flasher, remove the lower steering column cover and knee blocker. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8919 Junction Block Terminal Pins FLASHER MODULE OPERATION The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning functions and has been designed with internal relays to take advantage of low current switching requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring associated with its operation is terminated. The Junction Block is adjacent to and left of the steering column of the vehicle. To gain access to the device, remove the lower steering column cover and knee blocker. The combination flasher may be operated in its hazard warning mode either with or without the ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit must be completed to the module. While the combination flasher is idle, there is no current drawn through the module. The device does not become active until a signal ground circuit is supplied to either of the turn signal inputs or the hazard warning input. Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90 flashes per minute. Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of 300 mA and are provided to the flasher through the Junction Block from the multi-function switch that is mounted to the steering column. The hazard warning signal input is a low current ground drawing a maximum of 600 mA through the multi-function switch. Electronic Combination Flasher Circuit Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8920 Junction Block Terminal Call-Out CIRCUIT OPERATION The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/DRL. The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8921 Turn Signal Flasher: Description and Operation Combination Flasher Operation SYSTEM OPERATION The turn signals are actuated with a lever on the left side of the steering column just ahead of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: Combination flasher - Multi-function switch - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn signal ON. Circuit Operation The turn signal and hazard flasher system used in this vehicle is controlled by the combination flasher located in the junction block. On vehicles built for sale in Canada the Daytime Running Lamp (DRL) module is part of the combination flasher. Power for the combination flasher is supplied from two sources. One is a direct battery feed on circuit L9. This circuit is HOT at all times and protected by a 20 Amp fuse located in cavity 19 of the Power Distribution Center (PDC). The other power source is a fuse battery feed from the ignition switch on circuit F20. This circuit is HOT in the RUN position only and connects from the ignition switch to the combination flasher. Power for the F20 circuit is supplied on circuit A22/A2. This circuit originates at the PDC and is protected by a 40 Amp fuse located in cavity 2. LEFT TURN SIGNALS Circuit Operation When the operator selects the left turn signal, circuit L305 is connected to the Z1 ground circuit through the turn signal switch. The combination flasher senses the position of the switch and supplies power to the L61 and L63 circuits. Circuit L61 connects from the combination flasher to the left front turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the left cowl panel. Circuit L63 connects from the combination flasher to the left rear turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to the indicator lamp in the message center. RIGHT TURN SIGNALS Circuit Operation When the operator selects the right turn signal circuit L302 is connected to the Z1 ground circuit through the turn signal switch. The combination flasher senses the position of the switch and supplies power to the L60 and L62 circuits. Circuit L60 connects from the combination flasher to the right front turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the right cowl panel. Circuit L62 connects from the combination flasher to the right rear turn signal lamp. Ground for the lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to the indicator lamp in the message center. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8922 Turn Signal Flasher: Testing and Inspection Electronic Combination Flasher Circuit Electronic Combination Flasher With DRL Circuit The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This circuit (L09) is the only power feed to the combination-flasher/ DRL. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8923 Junction Block Terminal Call-Out Junction Block Terminal Call-Out With DRL The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to the module in a way that would power the system. This RUN/START circuit is brought into the junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is so equipped: - Back-Up Lamps - Electrochromic Inside Rear view Mirror - A/C Control Head - Mini-Trip Computer - ABS Module - Front Blower Relay Coil - Rear Blower Relay Coil - AWD Solenoids - Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically 5 mA of current while active. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8924 Combination Flasher Diagnosis (Part 1 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8925 Combination Flasher Diagnosis (Part 2 Of 2) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8926 Combination Flasher Diagnosis With DRL (Part 1 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8927 Combination Flasher Diagnosis With DRL (Part 2 Of 3) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8928 Combination Flasher Diagnosis With DRL (Part 3 Of 3) For diagnostic test procedures, refer to Combination Flasher Diagnosis tables. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation > Page 8929 Turn Signal Flasher: Service and Repair REMOVAL 1. Remove lower steering column cover. 2. Remove knee blocker. 3. Pull combination flasher from junction block. INSTALLATION 1. Push combination flasher to junction block. 2. Install knee blocker. 3. Install lower steering column cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb REMOVAL 1. From under front wheelhouse, remove access cover behind park and turn signal lamp. 2. Through access hole in wheelhouse, rotate park and turn signal socket counterclockwise one quarter turn. Park And Turn Signal Lamp Bulb 3. Pull socket from back of lamp. 4. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Through access hole in wheelhouse, insert socket into back of lamp. 3. Rotate park and turn signal socket clockwise one quarter turn. 4. Install access cover and verify lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 8935 Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal and Back-Up Lamp Bulb REMOVAL 1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4. Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter panel. Tail, Stop, Turn Signal And Back-Up Lamp Bulb 6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp. Pull Bulb From Socket 8. Pull bulb from socket. INSTALLATION 1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Multi-Function Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8939 Turn Signal Switch: Testing and Inspection To test turn signal, headlamp beam select and optical horn portion of the multi-function switch: 1. Remove the multi-function switch, refer to removal procedures. Turn Signal - Multi-Function Switch Pin Numbers 2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the above image for proper pin numbers and Turn Signal Multi-Function Switch Test table. TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 8940 Turn Signal Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. Turn Signal Multi-Function Switch 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Introduction General Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location section to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Augat Connectors 1. Disconnect battery 2. Disconnect the connector from its mating half/component. Augat Connector Repair 3. Push down on the yellow connector locking tab to release the terminals. Using Special Tool 6932 4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge must be placed in the locked position to prevent terminal push out. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Wiring Repair Wire Repair Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8959 When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Terminal Pick 6680 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8960 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8961 Heated Glass Element: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 8964 Heated Glass Element: Description and Operation INTRODUCTION Rear Window Defogger Heated Windshield Wiper De-icer The electrically heated Rear Window Defogger, Heated Power Side View Mirrors, and Heated Windshield Wiper De-icer is available on NS vehicles. The Rear Window Defogger system consists of two vertical bus bars linked by a series of grid lines on the inside surface of the rear window. The electrical circuit consists of the rear defogger switch in the HVAC and a relay with timer switch to turn OFF the system after ten minutes. The main feed circuit is protected by fuse one (40 amp) in the Junction Block. The rear defogger switch and relay also activates the heated power side view mirrors and heated windshield wiper de-icer. The HVAC rear defogger switch is protected by fuse ten (10 amp) in the Junction Block. The heated mirror circuit is protected by fuse 12 (10 amp) in the junction block. The heated windshield wiper de-icer circuit is protected by fuse 21 (25 amp) in the Junction Block. The Heated Windshield Wiper Deicer is also activated when the DEFROST mode is selected on the HVAC. In the DEFROST mode the rear defogger relay/timer is bypassed, the heated windshield wiper de-icer will stay ON until the another mode is selected. CAUTION: Since grid lines can be damaged or scraped off with sharp instruments, care should be taken in cleaning the glass or removing foreign materials, decals or stickers. Normal glass cleaning solvents or hot water used with rags or toweling is recommended. SYSTEM OPERATION HVAC Mounted Switch Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 8965 HVAC Control Panel/Rear Window Defogger Switch The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when the switch is activated. The switch energizes the timing circuit and activates the rear window defogger relay. The relay controls the current to flow to the grids of the rear window defogger, heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid Heated Glass Element: Testing and Inspection Detecting Breaks in Rear Window Defogger Grid Grid Line Test The horizontal grid lines and vertical bus bar lines printed and baked on inside surface of the window glass makes up an electrical parallel circuit. The electrically conductive lines are composed of a silver ceramic material which when baked on glass becomes bonded to the glass and is highly resistant to abrasion. It is possible, however, that a break may exist or occur in an individual grid line resulting in no current flow through the line. To detect breaks in grid lines, the following procedure is required: 1. Turn ignition and rear window defogger control switch ON. The indicator light should come on. 2. Using a DC voltmeter with 0 - 15 Volt range, contact vertical bus bar connecting grid lines on passenger side of vehicle at terminal A with negative lead of voltmeter. With positive lead of voltmeter, contact vertical bus bar on driver side of vehicle at terminal B. The voltmeter should read 10 - 14 Volts. 3. With negative lead of voltmeter, contact a good body ground point. The voltage reading should not change. A different reading indicates a poor ground connection. 4. Connect negative lead of voltmeter to terminal A on passenger side bus bar and touch each grid line at Mid-Point with positive lead. A reading of approximately 6 Volts indicates a line is good. A reading of 0 Volts indicates a break in line between Mid-Point C and terminal B. A reading of 10 - 14 Volts indicates a break between Mid-Point C and ground terminal A. Move toward break and voltage will change as soon as break is crossed. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 8968 Heated Glass Element: Testing and Inspection Defogger System Testing Electrically heated rear window defogger or the heated windshield wiper deicer operation can be checked on the vehicle in the following manner: 1. Turn the ignition switch to the ON position. 2. Using a ammeter on the battery, turn the rear defogger control switch to the ON position, a distinct increase in amperage draw should be noted. 3. The rear window defogger or the heated windshield wiper deicer operation can be checked by feeling the glass. A distinct difference in temperature between the grid lines and adjacent clear glass can be detected in 3 to 4 minutes of operation. Grid Line Test 4. Using a DC voltmeter contact terminal B with the negative lead, and terminal A with the positive lead. The voltmeter should read 10 - 14 Volts. 5. Indicator light illumination means that there is power available at the switch only and does not necessarily verify system operation. 6. If turning the defogger switch ON, no distinct current draw on the ammeter the problem should be isolated in the following manner: - Confirm that ignition switch is ON. - Ensure that the heated rear window or the heated windshield wiper deicer feed pigtail is connected to the wiring harness and that the ground pigtail is in fact grounded. - Ensure that the proper fuse in the Junction Block is OK. 7. When the above steps have been completed and the system is still inoperative, one or more of the following is defective: - HVAC switch - Rear window defogger relay in the relay bank. - Check for loose connector or a wire pushed out of connector. - Rear window or the windshield grid lines (all grid lines would have to be broken, or one of the feed pigtails not connected to the bus bar, for no ammeter deflection). 8. If turning the switch ON produces severe voltmeter deflection, the circuit should be closely checked for a shorting condition. 9. If the system operation has been verified but indicator LED does not light, replace switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Page 8969 Heated Glass Element: Service and Repair WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, HARMFUL IF SWALLOWED. AVOID CONTACT WITH SKIN AND EYES FOR SKIN, WASH AFFECTED AREAS WITH SOAP AND WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING; CALL A PHYSICIAN IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH WITH PLENTY OF WATER. USE WITH ADEQUATE VENTILATION DO NOT USE NEAR FIRE OR FLAME. CONTENTS CONTAINS 3% FLAMMABLE SOLVENTS. KEEP OUT OF REACH OF CHILDREN. The repair for the front windshield or the rear window grids are the same. The repair of grid lines and replacement of the terminal is possible using the Mopar® Repair Package or equivalent. 1. Clean area surrounding grid line or terminal by gently rubbing area with steel wool. 2. Wipe area with clean cloth soaked in alcohol or similar solvent. It is necessary that all contaminants be removed from repair area. 3. Remove package separator clamp and mix plastic conductive epoxy thoroughly. 4. For grid line, mark off area to be repaired with masking tape. 5. Apply conductive epoxy through slit in masking tape. Overlap both ends of the break. 6. For a terminal replacement, apply a thin layer of epoxy to area where terminal was fastened. 7. Apply a thin layer of epoxy on terminal and place terminal on desired location. To prevent terminal from falling off use a wooden wedge to secure it. 8. Carefully remove masking tape from grid line. CAUTION: Do not allow the laminated windshield glass surface to exceed 82 °C (180 °F) or the glass may fracture. The rear window glass surface should not exceed 204 °C (400 °F). 9. Allow epoxy to cure 24 hours at room temperature. 10. After epoxy is properly cured remove wedge from terminal and check the operation of the rear window defogger. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window and Vent Switch Test 1. Remove the driver or passenger door power window switch and bezel assembly from door trim panel. Power Window Master Switch Connector Driver Door Power Window Switch Test 2. Using an ohmmeter, Test driver door switch for continuity. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 8974 4. If the results are not OK, replace the switch. The driver door power window switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE. REMOVAL 1. Tape the window in its existing position to remove its weight from the regulator system. 2. Cut and remove the tie wrap at the window motor. Its no longer required. 3. Disconnect window motor wire connector from door harness. 4. Remove screws and nuts holding window motor to the inner panel. 5. Remove the motor from the door inner panel, let it hang from the cables. 6. With the cables still attached to the failed motor, Install the replacement motor to the door inner panel. Tighten down the screws and nuts to 3.4 to 4.5 N.m ( 30 to 40 in. lbs.) of torque. 7. Separate the failed motor from regulator by: - Removing the drum cover plate. Power Window Motor Removal - Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously. CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the cables unwind. INSTALLATION 1. Install the cable guide and drum into the replacement motor. CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor shaft by a slight rotation, then, the glass should be lowered a small amount approximately 1 to 2 inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance of a second person. 2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the wiring harness to the window motor connector. 4. Remove the tape holding the window in place and test window operation. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection Power Window Switch: Testing and Inspection Power Window and Vent Switch Test 1. Remove the driver or passenger door power window switch and bezel assembly from door trim panel. Power Window Master Switch Connector Driver Door Power Window Switch Test 2. Using an ohmmeter, Test driver door switch for continuity. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 3. Test passenger door switch for continuity. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 8983 4. If the results are not OK, replace the switch. The driver door power window switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down relay senses an amperage spike (motor pushing against down stop) in the feed circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an amperage spike will cause the switch to disconnect after approximately 11 seconds. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair Window Regulator: Service and Repair REMOVAL 1. Remove door trim panel and water shield. 2. Remove door glass retaining clips and allow glass to rest on bottom of door. 3. If equipped, disengage wire connector from power window motor. Front Door Glass Window Lift Guides 4. Loosen screws holding front and rear window lift guides to inner door panel. 5. Separate screw heads on lift guides from key hole slots in inner door panel. 6. Loosen screws holding regulator to inner door panel. 7. Remove regulator from inner door panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Page 8987 Front Door Window Regulator 8. Extract rear lift guide through inner door panel access hole. 9. Extract front lift guide through access hole. INSTALLATION 1. Insert front lift guide through access hole. Front Door Window Regulator 2. Insert rear lift guide through access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to hold regulator to inner door panel. 6. Place screw heads on lift guides in position through key hole slots in inner door panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and Repair > Page 8988 Front Door Glass Window Lift Guides 7. Tighten screws to hold front and rear window lift guides to inner door panel. 8. If equipped, engage wire connector into power window motor. 9. Install door glass. 10. Verify door glass alignment and operation. 11. Install water shield and door trim panel. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9001 Windshield Washer Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Turn Signal Multi-Function Switch 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 9005 Wiper Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Turn Signal Multi-Function Switch 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Rear Window Washer Rear Wiper Motor Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Rear Window Washer > Page 9013 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Front Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Front > Page 9016 Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 9020 Windshield Washer Pump: Diagrams Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove right front wheel. 3. Remove front wheelhouse splash shield. Windshield Washer Bottle 4. Disconnect wire connectors from the windshield and rear window washer pumps. 5. If washer bottle has fluid in it place a suitable drain pan under the hose connections. Front Washer Hose 6. Disconnect front washer hose at front wiper unit in the engine compartment. The front hose will be removed with the bottle. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 9024 Rear Washer Hose Routing 7. Disconnect hose from rear washer pump nipple. 8. Allow washer bottle to drain. 9. Remove screws holding washer bottle to front fender support and remove bottle. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection Windshield Washer Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9028 Windshield Washer Switch: Service and Repair WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES. REMOVAL 1. Release hood latch and open hood. Turn Signal Multi-Function Switch 2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch. INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk in either the right or left position and turning the steering wheel to ensure the automatic cancellation of the switch. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Verify wiper blade element condition and wiper arm spring tension. Run wipers in low speed mode while applying water to the windshield. Observe the wiper blade that is chattering or skipping across the windshield. If the wiper element is not rolling over when the wiper direction reverses, align the wiper arm. The extension bar portion of the wiper arm must be twisted in the proper direction to allow the wiper element to roll over when the direction reverses. 2. Place two small adjustable wrenches placed 50 mm (2 in.) apart on the wiper arm extension rod. 3. Twist the extension rod slightly in the opposite direction that the element is laying on the windshield while holding the wrench closest to the pivot stationary. 4. Repeat step Step 1, and align as necessary until wiper stops chattering and wipes the windshield clear. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm Wiper Arm: Service and Repair Wiper Arm CAUTION: The Driver side wiper arm must be parked above the passenger side. Failure to do so will result in damage to the arms, blades or system. REMOVAL 1. Disengage the clip holding outside end of the wiper arm pivot cover to the wiper arm. 2. Lift the arm cap upward. 3. Remove the nut holding wiper arm to the wiper pivot. Wiper Arm Removal 4. Using a suitable two jaw puller, separate the wiper arm from the wiper pivot. INSTALLATION 1. Verify that the wiper motor and linkage are in the park position. Wiper Arm Adjustment 2. Place the wiper arm in position over the wiper pivot. Refer to Alignment. 3. Install the nut to hold the wiper arm to the wiper pivot. Tighten nut to 35 N.m (26 ft. lbs.). 4. Push the arm cap cover down. 5. Engage clip to the hold outside end of wiper arm pivot cover to the wiper arm. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm > Page 9034 Wiper Arm: Service and Repair Rear Wiper Arm REMOVAL 1. Lift and hold wiper blade away from rear window. 2. Lift lock holding wiper arm to wiper pivot upward. 3. Allow wiper arm to rest against lock. Rear Wiper Arm 4. Pull wiper from pivot. INSTALLATION 1. Push wiper from pivot. 2. Disallow wiper arm to rest against lock. 3. Lower lock holding wiper arm to wiper pivot upward. 4. Lower and hold wiper blade away from rear window. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 9048 Wiper Blade: Testing and Inspection Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to the Wiper Arm Alignment. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Rear Wiper Blade Wiper Blade: Service and Repair Rear Wiper Blade REMOVAL Rear Wiper Arm 1. Lift wiper blade away from rear window. 2. Release latch holding blade to wiper arm. 3. Remove blade from wiper arm. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Rear Wiper Blade > Page 9051 Wiper Blade: Service and Repair Wiper Blade REMOVAL 1. Lift the wiper arm away from windshield. Windshield Wiper Blade 2. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm. 3. Remove the wiper blade from the wiper arm. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Rear Wiper Blade > Page 9052 Wiper Blade: Service and Repair Wiper Blade Element REMOVAL Windshield Wiper Blade 1. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm. Windshield Wiper Blade Element 2. Disengage clip holding the wiper element to wiper blade. 3. Pull the element from the claws on the wiper blade. INSTALLATION Wiper Blade And Element Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Rear Wiper Blade > Page 9053 1. Insert the element vertebra into claw at the open end of the wiper blade and through each claw location along the blade. 2. Engage clip to hold wiper element to wiper blade. 3. Test wiper effectiveness using washer mode and align if necessary. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9062 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9063 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9064 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9065 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor Technical Service Bulletin # 23-43-97A Date: 970912 Evaporator Housing - Water Leaks Onto The Floor NO: 23-43-97 Rev. A GROUP: Body DATE: Sep. 12, 1997 SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. ** ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES. MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager (International Market) NOTE: THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES. SYMPTOM/CONDITION: Several conditions can cause water to leak onto the carpet from the HVAC housing. These may include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the lower plenum drain hose. DIAGNOSIS: Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under flush. Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across the windshield and stuck to the cowl cover. Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the hood and stuck to the cowl cover. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9071 Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully seated and not restricted, kinked or plugged, see Figure 1. PARTS REQUIRED: AR (1) 05010842AA Deflector AR (2) 0153185 Screw AR (1) 04885330AA Super Kleen AR (1) 04318025 Sealant, Silicone REPAIR PROCEDURE: This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in the cowl plenum. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-50-02-93 Procedure A 0.5 Hrs. 23-50-02-94 Procedure B 1.2 Hrs. FAILURE CODE: XX - Service Adjustment Procedure A Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9072 1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95. 2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm (100 - 140 in. lbs.). 3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover. Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across. The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.). 4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e. kinks, tie straps too tight, foreign material in tubes, etc. 5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts. 6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water. 7. Ensure the lower plenum drain hose and grommet are seated. 8. With the engine running and HVAC blower set to the High speed position, spray water at less than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning properly, perform Procedure B. Procedure B 1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of the wiper arm pivot cover to the wiper arm and lift the arm cap upward. 2. Remove the nut attaching the wiper arm to the wiper pivot. 3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot. 4. Repeat steps 1-3 for the other wiper arm. 5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module. 6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper module. 7. Lower the hood and remove the cowl cover outboard attaching screws. 8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer nozzle. 9. Separate the cowl cover from the vehicle. 10. Open the hood. 11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine wiring harness from the wiper module connector. 12. Disconnect the washer hose from the wiper module. 13. Disconnect the two drain tubes from the bottom of the wiper module. NOTE: DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER, DAMAGE TO THE BRAKE SYSTEM MAY RESULT. 14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper module from the vehicle. 15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab closest to the center of the vehicle and bend it flush with the plenum floor. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9073 16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is inside the plenum, Figure 2. 17. Slide the deflector toward the passenger side of the vehicle and position it in front of and around the holes in the plenum floor. 18. Pull the outboard side of the deflector forward against the front plenum wall and attach a "C"-clamp or vise grip plier to hold the deflector in position, Figure 3. **19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in bottom flange of the deflector (Location 2 in Figure 3) as a guide to drill a 7/64 in. pilot hole in the plenum floor.** 20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector (Location 3, Figure 3). 21. Remove the holding device used in step 18 and remove all metal particles created by drilling the three pilot holes. 22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the deflector toward the center of the vehicle away from the holes in the passenger side of the plenum floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot print" area of the plenum. 23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of 2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum. NOTE: PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE EFFECTIVE. 24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 9074 deflector free of sealer. 25. Install the wiper module and cowl cover by reversing the removal procedure. 26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the base of the windshield and the drain tubes are connected to the wiper module. 27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35 Nm (26 ft. lbs.) 28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below 65°F. (18°C.) Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement Wiper Motor: Service and Repair Rear Wiper Motor Replacement REMOVAL 1. Remove rear wiper arm. 2. Open liftgate. 3. Remove liftgate trim panel. 4. Disconnect wire connector from rear wiper motor. Rear Window Wiper Motor 5. Remove screws holding rear wiper motor to liftgate. 6. Remove wiper motor from liftgate. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Rear Wiper Motor Replacement > Page 9077 Wiper Motor: Service and Repair Replacement REMOVAL 1. Remove the wiper arms. 2. Remove the cowl cover. Wiper Unit Wire Connector 3. Release the hood latch and open hood. 4. Disconnect the positive lock on the wiper unit wire connector. 5. Disconnect the wiper unit wire connector from the engine compartment wire harness. 6. Disconnect the windshield washer hose from coupling inside unit. 7. Disconnect the drain tubes from nipples on bottom of the wiper unit. 8. Remove nuts holding wiper unit to lower windshield fence. Wiper Unit 9. Remove bolts holding the wiper unit to the dash panel. 10. Lift wiper unit from weld-studs on lower windshield fence. CAUTION: Do not allow wiper unit to rest on brake master cylinder reservoir, damage to brake system can result. 11. Remove wiper unit. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the windshield wiper unit from vehicle. 2. Place the wiper unit on a suitable work surface. 3. Remove nuts holding the cowl cover brackets to the wiper unit. 4. Remove cowl cover brackets from the wiper unit. 5. Remove nuts holding linkage and motor mount plate to the wiper unit. Wiper Linkage 6. Remove the wiper linkage from the wiper unit. Wiper Motor Connector 7. Disconnect the wire connectors from back of the wiper motor. INSTALLATION - For Installation, reverse the above procedures. Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection Wiper Switch: Testing and Inspection To test the windshield wiper and washer portion of the multi-function switch: 1. Remove the multi-function switch. Windshield Wiper And Washer - Multi Function Switch Test 2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers. Switch Position = Resistance Value Between OFF = 6 AND 7 - MAX 1.0 Ohms Delay Position 1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6 AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256 Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5 Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY